Fringeless cleaning or dusting pad

ABSTRACT

A cleaning pad or cleaning article  1001  is disclosed. The cleaning article  1001  includes a combination of fibers  1003  bonded to an uncut solid unperforated base sheet  1002.  A first joining portion  1007  joins each of the one or more fibers to the base sheet  1002  and at least one second joining portion  1014  joins fibers  1003  in at least to the base sheet  1002.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. No. 11/373,931 filed Mar. 13, 2006, the entirety of which isincorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the field of cleaning devices such ashand held dusters and dust mops. More particularly, the presentinvention relates to an improved “fringeless” cleaning article orcleaning pad that exhibits more free fiber, greater fluffiness andgreater dust adhesion.

2. Discussion of the Related Art

For decades, hand held feather dusters, dust rags and other cleaningimplements have been used as cleaning tools for the removal of dustadhering to furniture such as dressers and coffee tables, electricalappliances such as computers, lights, interior walls, lintels and thelike, Thus, it is generally well known to remove dust or dirt fromfloors, furniture, and other household surfaces by rubbing a dust rag,cloth or other cleaning implement against the surface such that the dustor dirt adheres to the cleaning implement.

Throughout the last half-century, new cleaning implements have beendeveloped to assist the individual in dusting and similar cleaningchores. While hand held dusters and other cleaning implements aregenerally well known in the art, numerous drawbacks exist with thecurrent commercially available designs.

In general, the majority of improvements to hand held dusters and mopshave been directed at improving the basic mechanical components of thecleaning device. These improvements have been directed at providing aninexpensive yet robust implement for dry dusting or cleaning. However,notably absent in the prior art is any attempt to provide a hand heldcleaning implement that allows for selective wet, damp or dry dusting.

The addition of water or other cleaning solution to most cleaning padsor systems has been known to increase the efficiency of the cleaningdevice in absorbing dust and other debris. Despite this knowledge, thereare presently no hand held cleaning systems that include an attachedwater or cleaning fluid reservoir accessible on the cleaning implementto allow a user to single handedly alternate between wet, damp or drydusting. To date, prior art dusting and cleaning devices require a userto obtain a separate spray bottle or other liquid application means ifone desires wet dusting or cleaning. In light of the need for a wet ordamp dusting or cleaning system and methods, there is an additional needfor improvements in the cleaning solution associated with such systemsand methods.

There is an additional need to improve the cloths associated with suchsystems and how they are used. Many of the known disposable dusting orcleaning cloths include a base sheet that includes a plurality of stripsor cuts. It has been found that such strips may actually entangle thefiber bundle resulting in a less open fiber bundle with a lower amountof free fiber. A fringeless base sheet has been shown to provide agreater amount of open fiber.

While some improvements to dusting cloths are disclosed in the art,there remains a need for an improved cleaning pad and fiber orientationthat maximizes the wet and dry absorbency of the dusting pad, while atthe same time fully facilitating the advantages of the liquid in thecleaning system.

SUMMARY AND OBJECTS OF THE INVENTION

Consistent with the foregoing, and in accordance with the invention asembodied and broadly described herein, preferred embodiments of acleaning article or cleaning pad are disclosed in suitable detail toenable one of ordinary skill in the art to make and use the invention.

In a first embodiment, a cleaning article includes a fusible base sheethaving an unperforated, uncut outer edge, a fusible holding sheet and afiber bundle layer including fusible fibers. The fiber bundle layer islaid on one side of the base sheet and the holding sheet is laid on theother side of the base sheet. Preferably, the fiber bundle layer and theholding sheet are fusion-bonded in a direction to cross fibers in thefiber bundle layer, and the holding sheet is shorter than the basesheet. A holder and two holding spaces are provided between the basesheet and the holding sheet and the holder is detachably inserted intothe holding spaces.

In one embodiment, the outer edge of the base sheet is rectangular andis defined by a straight uncut upper edge, a straight uncut lower edgeand two straight unperforated, uncut side edges. The outer edge may belinear or nonlinear.

In yet another embodiment, the holder includes a handle portion havingan opening configured to allow access to a cradle and a cleaning padsupport member moveably attached to the handle portion. The supportmember may be moveable between a first cleaning position and a secondcleaning pad liquid application position. A cleaning fluid dispenser,such as a pump spray bottle, may be placed within the cradle.

In yet another embodiment, a cleaning article having a brush portion,includes a fusible sheet having an unperforated, uncut outer edge and afiber bundle layer including fusible fibers. The fiber bundle layer isfusion-bonded to the fusible sheet to provide a brush portion and twoholding spaces into which a holder is to be inserted. The brush portionis defined by the fusible sheet and fibers of the fiber bundle layer.

In another embodiment, the cleaning article is attached to a handledefining an interior recess for receiving a fluid reservoir, and acleaning article support pivotably attached to the handle capable ofpivoting rearwardly from a cleaning position and a fluid reservoirattached to the handle in the cradle. The reservoir is capable ofapplying fluid to a surface to be cleaned and to the surface of thefiber bundle layer.

In one embodiment, the cleaning article support includes a pair ofparallel laterally extending attachment prongs. The attachment prongsmay include a plurality of projections extending generally verticallyfrom the prongs and have an angled side sloping away from the handle.The support may also include a pivot member at one end including aplurality of indentations configured to receive a semi-flexibleengagement tab projecting downward from the handle.

In yet another embodiment, a cleaning article includes a soft andfusible base sheet including a solid uncut outer edge and one or morefiber bundle layers including fusible filaments. One or more fiberbundle layers are laid on one side of the base sheet and a first joiningportion joins each of the one or more fiber bundle layers to the basesheet. At least one second joining portion joins fibers in at least oneof tile one or more fiber bundle layers to the base sheet.

In another embodiment, the cleaning article further comprises a handleportion defining a cradle for a fluid reservoir and a cleaning articlesupport member attached to the handle portion. The cleaning articlesupport member is movably attached to the handle portion. In oneembodiment, the cleaning article support member is pivotally attached tothe handle portion. In an alternative embodiment, the cleaning articlesupport member is slidably attached to the handle portion. In a finalembodiment, the cleaning article support member includes a detachablecleaning fluid dispenser within the cradle.

These, and other, aspects and objects of the present invention will bebetter appreciated and understood when considered in conjunction withthe following description and the accompanying drawings. It should beunderstood, however, that the following description, while indicatingpreferred embodiments of the present invention, is given by way ofillustration and not of limitation. Many changes and modifications maybe made within the scope of the present invention without departing fromthe spirit thereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

A clear conception of the advantages and features constituting thepresent invention, and of the construction and operation of typicalmechanisms provided with the present invention, will become more readilyapparent by referring to the exemplary, and therefore non-limiting,embodiments illustrated in the drawings accompanying and forming a partof this specification, wherein like reference numerals designate thesame elements in the several views, and in which:

FIG. 1 is a perspective view of a first embodiment of an assembledcleaning system capable of wet or dry cleaning, the cleaning systemshown in a first cleaning position;

FIG. 2 is an exploded perspective view of the component parts of thecleaning system illustrated in FIG. 1;

FIG. 3 is a side view of the cleaning system in the storage position;

FIG. 4 is a side view of the cleaning system in the liquid applicationposition with the cleaning pad support and a human finger shown inphantom;

FIG. 5 is a perspective view of the underside of the cleaning systemillustrating a preferred construction of the fluid-receiving cradle;

FIG. 6 is a vertical cross-sectional view of the cleaning system takenalong the longitudinal axis of the device illustrated FIGS. 1-5;

FIG. 7 is a sectional view taken along line 5-5 of FIG. 6;

FIG. 8 is a sectional view taken along line 6-6 of FIG. 6;

FIG. 9 is a sectional view taken along line 7-7 of FIG. 6;

FIG. 10 is side view of a cleaning system in the liquid applicationposition further illustrating an alternative embodiment of the cleaningpad attached to the cleaning system;

FIG. 11 is an exploded partial perspective view of the pivot assembly ofthe inventive cleaning system illustrated in FIGS. 1-5;

FIG. 12 is an exploded perspective view of the component parts of analternative embodiment of the cleaning system;

FIG. 13 is a vertical cross-sectional view of the alternative cleaningsystem illustrated in FIG. 12 taken along the longitudinal axis of thesystem;

FIG. 14 is a bottom plan view of one preferred embodiment of thecleaning pad of the cleaning system;

FIG. 15 is a plan view of the base sheet of the cleaning padillustrating the preferred bonding regions;

FIG. 16 is a cross-sectional view of the cleaning pad of FIG. 14 takenalong line A-A;

FIG. 17 is a cross-sectional view of the cleaning pad of FIG. 14 takenalong line B-B;

FIG. 18 is a top plan view of another preferred cleaning pad;

FIG. 19 is a cross sectional view of FIG. 18 taken along line C-C;

FIG. 20 is a bottom plan view of the cleaning pad illustrated in FIG.18;

FIG. 21 is a cross-sectional end view of the cleaning pad illustrated inFIG. 18 taken along line D-D;

FIG. 22 is a top plan view of one embodiment of a retaining sheet foruse with the cleaning pad;

FIG. 23 is a cross sectional end view of the retaining sheet taken alongline G-G of FIG. 22;

FIG. 24 is a perspective view of the placement of the retaining sheetonto the base sheet of the cleaning pad;

FIG. 25 is a plan view of a base sheet of the cleaning pad illustratingan alternative bonding orientation and an uncut outer edge;

FIG. 26 is a plan view of a base sheet of the cleaning pad illustratinganother alternative bonding orientation;

FIG. 27 is a plan view of a base sheet of the cleaning pad illustratinganother alternative bonding orientation and triangular shaped spots;

FIG. 28 is a plan view of a base sheet of the cleaning pad illustratinganother alternative bonding orientation and star shaped spots;

FIG. 29 is a plan view of a base sheet of the cleaning pad illustratinganother alternative bonding orientation;

FIG. 30 is a top plan view of the cleaning pad illustrated in FIG. 18using a base sheet without strips;

FIG. 31 is a perspective view of the placement of the retaining sheetonto the base sheet of the cleaning pad illustrated in FIG. 30;

FIG. 32 is a plan view of a base sheet with a non linear outer edge; and

FIG. 33 is a perspective view of a prior art base sheet.

FIG. 34 is a perspective view showing an additional embodiment of acleaning pad or cleaning article according to an alternative embodimentof the invention;

FIG. 35 is a partially enlarged perspective view showing a brush portionof the cleaning article of FIG. 34;

FIG. 36 is a perspective view showing the cleaning article of FIG. 34from the back side;

FIGS. 37A and 37B are perspective views showing a base sheet of thecleaning article of FIG. 34 and a laminate of the base sheet and a firstfiber bundle layer, respectively;

FIG. 38 is a perspective view showing a laminate of a second fiberbundle layer and a secondary sheet of the cleaning article of FIG. 35;and

FIG. 39 is a perspective view showing a modification of the cleaningarticle of the cleaning article of FIG. 35.

In describing the preferred embodiment of the invention, which isillustrated in the drawings, specific terminology will be resorted tofor the sake of clarity. However, it is not intended that the inventionbe limited to the specific terms so selected and it is to be understoodthat each specific term includes all technical equivalents, whichoperate in a similar manner to accomplish a similar purpose. Forexample, the word connected or terms similar thereto are often used.They are not limited to direct connection but include connection throughother elements where such connection is recognized as being equivalentby those skilled in the art.

DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention and the various features and advantageous detailsthereof are explained more fully with reference to the non-limitingembodiments described in detail in the following description.

1. System Overview

In a basic form, the inventive cleaning pad or cleaning article includesa cleaning pad that includes a combination of fiber bonded to a basesheet. The base sheet or nonwoven sheet preferably includes a uniformouter edge, such as a solid, unperforated, uncut outer edge and acombination of fibers connected to the nonwoven sheet. The inventivecleaning pad results in a fiber layer that is more open, fluffier andexhibits greater dust adhesion.

2. Detailed Description of Preferred Embodiments

Specific embodiments of the present invention will now be furtherdescribed by the following, non-limiting examples which will serve toillustrate various features of significance. The examples are intendedmerely to facilitate an understanding of ways in which the presentinvention may be practiced and to further enable those of skill in theart to practice the present invention. Accordingly, the below examplesshould not be construed as limiting the scope of the present invention.

a. The Apparatus

Turning initially to FIGS. 1 and 2, the cleaning system 20 of theinventive method is illustrated according to a preferred embodiment ofthe present invention. Cleaning system 20 is generally comprised of acleaning tool 22, including a holder, handle portion or handle 24 andpivotally attached cleaning pad support member, cleaning implementsupport member, cleaning article support or cleaning media support 26, aliquid delivery system, cleaning fluid dispenser or reservoir 30 and acleaning pad, cloth, cleaning article or cleaning media 28 attached tothe cleaning tool 22 via the cleaning pad support member 26.

Holder or handle portion 24 is preferably a curved ergonomicallydesigned member configured to comfortably fit within the palm of a handof a user. Handle portion 24 includes an integral top 29, first sidewall21 a, second sidewall 21 b, rear wall 23 and bottom 31. Handle portion24 may be constructed from a variety of synthetic resins, plastics orother suitable materials. In the preferred embodiment, handle portion 24is constructed from polypropylene. Although the handle portion 24 may beconstructed in a wide variety of sizes depending on the intended use, inthe preferred embodiment, handle portion 24 is approximately 8.5 incheslong, 1.3 inches wide and 1.7 inches high. The preferred dimensionsallow for ease of use, manipulation, packaging, shipping and storage ofthe cleaning system 20 as well as increasing the overall ergonomics ofthe design. Handle portion 24 may be constructed in a variety of colorsfor increased aesthetic appeal. It may additionally be constructed froma translucent material.

As will be described in greater detail below, handle portion 24preferably defines a fluid reservoir-receiving cradle, recess or bay 36(FIG. 6). In the preferred embodiment, the insertion of the fluiddispenser or reservoir 30 into the cradle 36 finishes the ergonomicdesign or form of the handle portion 24. Thus, the palm of a user's handextends over the top 29 handle portion 24 and the user's fingers extendat least partially around the fluid reservoir 30 when using the device.Additionally, the preferred curved ergonomic design of the of the handleportion 24 is constructed in a manner such that the pivot point definedby the pivot member receiving cavity 50 is located below the horizontalplane defined by the fluid reservoir 30 within the cradle 36. Such anorientation is advantageous in maximizing fluid application as discussedin greater detail below.

Near the center of the handle portion 24 is preferably an opening orhole 32 extending through handle portion 24 into the bottom 31 of thehandle portion. In the illustrated embodiment, opening 32 isapproximately 2.5 inches from a pivot member receiving cavity 50 locatedat the forward end 25 of the handle portion 24. As illustrated in FIG.4, opening 32 provides a user single-handed access into a fluidreservoir-receiving cradle, recess or bay 36 defined in the bottom 31 ofthe handle portion 24. Near the forward end 25 of the handle portion 24,above the pivot member receiving cavity 50 is a cantilevered pivotengagement tab 38, extending downwardly into the pivot member receivingcavity 50 described in greater detail below.

FIG. 2 illustrates one preferred embodiment of a fluid reservoir 30 ofthe cleaning system 20. In the illustrated embodiment, fluid reservoir30 is in the form of a fluid dispenser or a pump-activated spray bottleconfigured to retain water or a specialized fluid. The fluid may becomprised of a variety of known products. Preferably the fluid isselected from the commercially available Pledge® Multi-Surface Cleaner,Pledge® Wood and Glass Cleaner, End Dust®, Fantastic® all purposecleaner, Windex® glass cleaner, anti-bacterials such as Oust® or Lysol®,fragrances such as Glade®, leather or vinyl treatment such as ArmorAll®, fabric protectors such as Scotch Guard®, or fabric fresheners suchas those manufactured by S.C. Johnson & Son, Inc. of Racine, Wis., orFabreze®. The fluid may alternatively generally comprise, withoutlimitation: any all-purpose cleaner, anti-allergen or antigenecityreducing compound, oil or water based dust inhibitor, anti-static,anti-microbial, antibacterial, sanitizing and de-odorizing agent,dusting agent glass cleaner, furniture polish, leather or vinyltreatment, other cleaning agent, wax, polish or shining agent, softeningagent, friction-enhancing compound, perfumes, dish cleaner, soap, insectrepellent or insect barrier, exfoliator or other personal care product,paint for sponge painting or other application, water out emulsions, oilout emulsions, dust mite killer or repellant, abrasive cleaner, shoepolish, pet sanitation products, etc.

As illustrated in FIG. 2, the preferred spray bottle is a generallycylindrical bottle having an integral bottom 51, sidewall 53, second 55and third 59 sections. A spray cap or nozzle 61 is screwed or pressfitted onto the top of the spray bottle. The spray cap 61 includes apair of opposed flats 63 a, 63 b configured to selectively engageflanges 71 a, 71 b of the fluid reservoir-receiving cradle 36 (FIG. 6).Alternatively, a system of tabs and grooves could be used to form asimilar locking mechanism. The spray cap 61 could alternatively includea one sided flat button or a tapered button. In addition to theillustrated spray bottle, the fluid reservoir 30 could take a variety offorms including but not limited to an aerosol package, a deformablehandle or reservoir that dispenses fluid by squeezing, a squirt gun or aflexible pouch with an attachable spray nozzle. While the fluidreservoir 30 is illustrated as fitting within the cradle 36 of thehandle portion 24, the fluid reservoir may alternatively completely formthe handle of the system, having only the upper portion of the cleaningsystem attached (i.e. the pivot member and the attachment members).

It should be recognized that opposed flats 63 a, 63 b of the spray cap61 provide for a tight fit within the handle portion 24, and furtherserve to properly orientate the fluid reservoir 30 within the cleaningsystem 20. Alternatively, it is understood that the fluid reservoir 30could include other uniquely designed contours that allow for a matingtight fit within the fluid reservoir-receiving cradle 36.

FIG. 5 better illustrates the bottom 31 of the handle portion 24defining the fluid reservoir-receiving cradle 36. Cradle 36 is generallydefined by a lower support 37, handle portion sidewalls 21 a, 21 b andtwo U-shaped supports or rails 44 and 46 configured to receive the fluidreservoir 30 of the preferred embodiment. In the preferred embodiment,lower support 37 is comprised of a plurality of ribs 39 extending fromthe inner side of rear wall 23 of handle portion 24. The forward ends 43of ribs 39 define the lower support 37 configured to support the bottom51 of the fluid reservoir 30. In the preferred embodiment, ribs 39include a central rib 45 having a length roughly equal to diameter ofthe bottom of the fluid reservoir 30. The remaining ribs 39 defineprogressively shorter lengths, thereby tapering off from the central rib45 and supporting the remainder of the circular bottom of the fluidreservoir 30. As best shown in FIG. 9, a pair of triangular retentiontabs 42 a, 42 b extend along opposed sides of the cradle 36 near thelower support 37. Retention tabs 42 a, 42 b are configured tofrictionally engage and retain the lower sidewall 53 of the fluidreservoir 30. Extending forwardly from the retention tabs 42 a, 42 b,sidewalls 21 a, 21 b further define the sides of the fluidreservoir-receiving cradle 36 and are spaced in a manner to tightly fitaround the sidewall 53 of the fluid reservoir 30.

While in the illustrated preferred embodiment, the fluid reservoir 30 ispress fit or friction fit within the cradle 36 of the handle portion 24,it is recognized that alternative configurations could be utilized toretain the fluid reservoir 30 within the handle portion 24. For example,Velcro® or rubber bands could be included on a segment of the handleportion 24 in order to retain the fluid reservoir 30 within the handleportion 24. Other support structures or retaining features could behingedly or otherwise attached to the handle portion to retain the fluidreservoir within the handle portion.

Near the forward end of the fluid reservoir-receiving cradle 36 is afirst U-shaped bottleneck receiving support 44. First bottleneckreceiving support 44 is configured to press fit around, receive andretain the fluid reservoir 30 of the preferred embodiment. Asillustrated in FIGS. 6 and 8, first bottleneck receiving support 44 isconfigured to press fit around the fluid reservoir 30 near the junction59 of the second 55 and third 57 sections of the reservoir 30.

Slightly forward of the first bottleneck receiving support 44 is asecond U-shaped spray cap receiving support 46. Spray cap receivingsupport 46 is configured to press fit around, retain and orientate thespray cap 61 of the fluid reservoir 30. As best illustrated in FIGS. 5and 6, spray cap receiving support 46 is defined by a pair of flanges 71a, 71 b extending from the inner side of opposed sidewalls 21 a, 21 b.Flanges 71 a, 71 b are configured to press fit around flats 63 a, 63 bof fluid reservoir spray cap 61 when the reservoir is placed within thecradle 36. The tight fit defined by flanges 71 a, 71 b and flats 63 a,63 b serves to properly orientate spray cap 61 within the fluidreservoir-receiving cradle 36 such that spray cap 61 faces in adirection away from the cradle 36. Forward of the opening 32, are aplurality of structural support ribs 48 extending forwardly towards thepivot member receiving cavity 50.

Turning now to FIGS. 6 and 11, at the forward end 25 of the bottom 31 ofthe handle portion 24 is a pivot member receiving cavity 50. Pivotmember receiving cavity 50 is defined between integral opposed ears 49a, 49 b (FIG. 7) located at the forward end 25 of the handle portion 24.Ears 49 a, 49 b include opposed grooves 52 a, 52 b on their inner cavitysurface configured to slidably engage the axles 80 a, 80 b of a circularpivot member 82 during assembly. Grooves 52 a, 52 b have a width that isequal to or slightly wider than the diameter of the axles 80 a, 80 b ofthe circular pivot member 82. It is understood that grooves 52 a, 52 band the pivot member receiving cavity 50 are configured to accommodate avariety of alternative cleaning pad support members 26 or other cleaningimplements having pivot members 82 attached at their proximal ends,

At the terminal end of the grooves 52 a, 52 b, are pivot holes 54configured to receive the axles 80 a, 80 b of the circular pivot member82 and allow pivotable motion therein. A curved slot 83 extendslaterally from grooves 52 a, 52 b and defines a passage configured toallow the movement of circular pivot retention tabs 95 extending fromthe pivot member 92. On opposed sides of the forward end of the pivotmember receiving cavity 50 are circular pivot retention tab holes 87configured to engage and receive the circular pivot retention tabs 85located on the pivot member 82.

Projecting downwardly from the top 29 of the handle portion 24 into thepivot member receiving cavity 50 is a resiliently biased semi-flexiblepivot engagement tab 38. Engagement tab 38 is comprised of a first end39 attached to the handle portion 24 and a second free end 91 configuredto engage notches 102, 104, 106 on the outer surface of the pivot member82 as will be described in greater detail below.

Attached within the pivot member receiving cavity 50 of the handleportion 24 is the cleaning pad support member 26. Cleaning pad supportmember 26 is comprised of an integral circular pivot member 82, linkingsection 93 and support head generally designated 92. Circular pivotmember 82 includes integral axles 80 a, 80 b on its opposed lateralsides. As best shown in FIG. 11, axles 80 a, 80 b are configured to fitwithin pivot holes 54 and rotatably pivot therein. Pivot member 82 alsoincludes a circular pivot retention tab 95. Circular retention tab 95 isconfigured to fit within retention tab holes 87 and support the systemin the cleaning position. Pivot member 82 defines three notches orindentations 102, 104, 106 corresponding to alternative positions of thecleaning pad support member 26. A cleaning position notch 102, liquidapplication notch 104 and storage position notch 106 are defined on theexternal surface of the pivot member 82. In general, the preferred pivotassembly requires about between 2-3 lbf of pivot force in order torotate it.

Integral with and extending from the pivot member 82 is the linkingsection 93 and support head 92. In the preferred embodiment support head92 of cleaning pad support member 26 includes a pair of parallelattachment members or attachment prongs 108 a, 108 b configured toengage the pockets or sleeves 110 a, 110 b of a cleaning pad 28 as isgenerally known in the art (FIG. 2). Attachment members 108 a, 108 b maybe spaced apart in a variety of configurations, however, in thepreferred embodiment, attachment members 108 a, 108 b have a total widthof about 1.25 inches from opposed outside lateral edges. The preferredattachment members 108 a, 108 b are about 6.75 inches long, about 0.75inches thick, and about 0.80 inches wide, Attachment members 108 a, 108b define a rounded leading edge 107 configured for ease of insertioninto the sleeves 110 a, 110 b of cleaning pad 28. It is recognized thatalthough the preferred embodiment illustrates a pair of attachmentmembers 108 a, 108 b multiple configurations may be utilized. Forexample, a single, wider attachment member could be utilized.Alternatively, three or more attachment members could be utilized.

Attachment members 110 a, 108 b may include a plurality of spacedcleaning pad retaining tabs, barbs or projections 112 projecting fromtheir upper surface 105. In the illustrated embodiment, retaining tabs112 are triangular-shaped tabs having a first wall 114 extending in agenerally vertical direction from the upper or lower surface of theattachment members 108 a, 108 b and a second angled wall 116 slopingfrom the upper edge of the first wall 114 towards the distal end of theattachment members 108 a, 108 b . Tabs 112 are preferably raised about0.050 inches from the attachment members 108 a, 108 b. The uniquetriangular configuration of the retaining tabs 112 serves a dualfunction. The angled wall 116 allows for ease of placement of thecleaning pad 28 on the attachment members 108 a, 108 b during assembly,while the vertical first wall 114 retains the cleaning pad 28 on theattachment members 108 a, 108 b during the cleaning motion.

In addition to the unique configuration of the retaining tabs 112, theirorientation on the attachment members 108 a, 108 b also serves tomaintain the cleaning pad 28 on the attachment members 108 a, 108 b. Inthe illustrated embodiment, the retaining tabs 112 are staggered andinclude a leading tab 115, three intermediary tabs 117 and a trailingtab 119. In the illustrated embodiment, each attachment member 108 a,108 b includes five retaining tabs 112. Testing has illustrated thatwhen the retaining tabs 112 are spaced an equal distance from oneanother, their retention function is not as great as when the tabs areplaced in the staggered configuration illustrated in the preferredembodiment. In the preferred embodiment the first tab is spaced 1.0inch, the second is spaced 2.0 inches, the third 2.5 inches, the fourth3,0 inches and the fifth 4.0 inches from the rounded leading edge 107.

In one embodiment the attachment members 108 a, 108 b may be expandable,inflatable, partially inflatable, or include an inflatable portion. Theinflatability provides for an improved fit of the cleaning pad 28 on theattachment members 108 a, 108 b as well as facilitating hands freeremoval of the cleaning pad 28 from the attachment members 108 a, 108 b.

Cleaning pad or cleaning article 28 is generally known in the art andcomprised of a combination of fibers defining a cleaning surface 111 andattachment portion 113 (FIG. 1). The cleaning pad 28 may, for example,include a plurality of fluffed nonwoven fabrics made of syntheticresins, which may be welded to one another. The pad may include fibersconstructed from PP, PE, PET fibers in a variety of alternativepercentages by weight In the illustrated embodiment attachment portion113 defines a pair of pockets or sleeves 110 a, 110 b configured toreceive the attachment members 108 a, 108 b of the cleaning pad supportmember 26. Cleaning pad 28 is preferably, a 20 g/sqm spun lace clothwith between 1-4% mineral oil manufactured by Haso Corporation of Japan.Such cleaning or dusting pads are described in PCT/JP2004/10507.

When the cleaning system 20 is used, the sleeve-like cleaning pad 28 ismounted over the attachment members 108 a, 108 b so that all of theretaining tabs 1 12 are within the sleeves 110 a, 110 b. The retainingtabs 112 are, in this configuration, thus capable of being fullyenclosed by the cleaning pad 28, avoiding the possibility of theattachment members 108 a, 108 b scratching delicate furniture or otheritems being contacted.

The cleaning surface 111 of cleaning pad 28 may be comprised of apolymer that allows for the spontaneous transport of aqueous fluids.Such polymers are described in, for example, U.S. Pat. Nos. 5,723,159,5,972,505 and 5,200,248 the disclosures of which are expresslyincorporated by reference.

It should be recognized that the polymer fibers of the cleaning pad cantake a variety of forms to increase various performance characteristicsof the cleaning system 20. Standard circular fibers may be used, as isgenerally known in the art. Alternatively, the individual fibers on thecleaning pad may be lobed in the form of loose tow fibers. The uniquelobed configuration creates channels within the individual fibersenabling improved capillary action on each individual fiber andincreasing the overall cleaning or dusting surface area therebyincreasing the overall efficiency, e.g., of both wet and dry dusting.The higher surface area results in an increase in the proportion ofparticles adhering in the grooves or channels and results in dustparticles being “trapped” within the grooves of the lobed fiber. Thelobed fibers generally exhibit improved dust retention, more efficientwet wiping and longer life than standard circular fibers. Furthermore,the lobed fibers can be made stiffer thereby generating a higher wipingpressure in a smaller contact area. It is understood that the inventivelobed fibers could be comprised of a multitude of polymers with PP, PEor PET being recognized as the most cost effective alternatives.Alternatively acrylic or biodegradable polymers could be utilized.

In another alternative embodiment, the cleaning pad 28 may includestiffer or strut fibers attached to mass of tow fibers. In thisarrangement, the stiffer fibers (usually in the range of about 0.3 mm)carry the majority of the stress applied to the cleaning pad 28. The towmay be linked to the stronger fibers by entanglement at the outer endsof the fiber The stiffer fibers result in a cleaning pad 28 that isspringy resulting in a more desirable feel of applied force for users.The stiffer fibers can further be utilized to clean difficult areas suchas crevices, blinds or screens. The stiffer fibers have the furtheradvantage in that they keep the tow volume expanded, thereby increasingdust migration into the tow fibers.

In yet another alternative embodiment, the cleaning pad 28 could includeabsorbent materials in particulate form fixed onto the remaining fibersof the cleaning pad 28. The absorbent materials may take the form ofknown super absorbent polymers SAP. The SAPs may be, for example,acrylic based polymers applied as a coating or turned into fibersdirectly. Such commercially available SAPs generally include X-linkedpolyacrylic acids or X-linked starch-acrylic-acid-graft-polymers, thecarboxyl groups of which are partially neutralized with sodium hydroxideor caustic potash. The SAPs may be made by such processes as a solventor solution polymerization method or the inverse suspension or emulsionpolymerization method. Such SAPs are disclosed in, for example, U.S.Pat. No 6,124,391.

The absorbent materials increase the overall absorbency of the fibers,prevent the fibers from packing close together into a fiber mass, andenhance the friction of the fibers. The “string of pearls” arrangementalso allows for strategically placed high absorbency regions on thecleaning pad. For example, if it is desirable to have the forward end ofthe cleaning pad 28 be more absorbent than the remainder of the cleaningpad 28, the forward end could include a higher percentage of theparticulate absorbent materials.

The cleaning pad 28 could also include fibers that are formed intohelices. Such fibers can be formed by drawing fiber bundles over a bladeor heating coaxial bicomponent fibers. The resulting helical fibersexhibit a fluffier texture and more attractive appearance while at thesame time increasing the volume (while using less fiber) and dustretention of the duster. The helical nature of the fibers is alsoadvantageous in that they allow coarse fibers to feel softer due to thespring effect. Furthermore, the fibers gradual loss of the helicalnature, can serve as an indication of the effective life of the cleaningpad.

It should be recognized that none of the aforementioned fiber materialsor configurations are exclusive. The cleaning pad could includestrategic combinations of the various fibers and other known fibers. Inone example, the cleaning pad may be comprised of between 25-100% of thelobed fibers by weight.

Similarly, although the preferred embodiment discloses a single cleaningsurface 111, the invention is in no way limited to such a singlecleaning surface. To the contrary, numerous alternative configurationsare within the scope of the present invention. For example, theinventive pad could include multiple cleaning surfaces, with alternateor similar fiber configurations to accommodate various cleaningfunctions. In one embodiment, a cleaning pad 28 could be two sided withone side of the cloth for dusting and the alternate side of the cleaningpad 28 for cleaning. This could also be accomplished by turning the pad“inside out” to expose a new clean surface, Alternatively, a triangularor other multi-sided cleaning pad 28 could be utilized. Circularcleaning pads are also envisioned and within the scope of the presentinvention. In general, a variety of cleaning pad 28 shapes orconfigurations could be utilized to maximize the various properties ofthe cleaning pad 28 and selected fibers.

As noted above, the orientation and type of fibers utilized on thecleaning pad 28 could include a wide variety of alternatives. Forexample and in no way limiting, the cleaning pad 28 could include agenerally fluffy pad including a flat center strip around the areadefined by the pockets or sleeves 110 a, 110 b. Such an orientation mayincrease the surface area and exhibit a better efficacy. Additionally,the center strip could include an absorbent pillow or tube extendingdown the center of the cleaning pad 28. Such an absorbent pillow couldprovide an area of high absorbency on the cleaning pad 28. Variousalternative combinations are envisioned including, for example, cleaningpads consisting of alternating sections of sponges, feather-likestructures, micro-fibers or cellulose foam. Wood pulp is preferred.

The cleaning pad 28 could also include a fluffy cloth with a hydrophilicadditive to improve the absorbency of water. Such hydrophilic additivesinclude but are not limited to glycerin and glycols. The cleaning pad 28could also be comprised entirely of an absorbent material such as Rayon.

The cleaning pad 28 or cleaning pad support member 26 could also includea piezoelectric crystal to impart an electrostatic charge on thecleaning pad during use to increase dust retention. Such crystals aregenerally known and typically generate a charge when subjected tomechanical stress. Examples of materials that can be used include butare not limited to quartz analogue crystals like berlinite (AlPO₄) andgallium orthophosphate (GaPO₄) and ceramics with perovskite ortungsten-bronze structures (BaTiO₃, KNbO₃, LiNbO₃, LiTaO₃, BiFeO₃,Na_(x)WO₃, Ba₂NaNb₅O₅, Pb₂KNb₅O₁₅). Additionally some Polymer materialslike rubber, wool, hair, wood fiber, and silk exhibit piezoelectricityto some extent and may be also utilized. Additionally, the polymerpolyvinylidene fluoride, (—CH₂—CF₂ —), which exhibits piezoelectricityseveral times larger than quartz may be used.

The cleaning pad 28 may also include a portion of an unbonded webmaterial, as described in U.S. Pat. No. 5,858,112, issued Jan. 12, 1999to Stokes et al. and U.S. Pat. No. 5,962,112, issued Oct. 5, 1999 toHaynes et al. or other material such as described by U.S. Pat. No.4,720,415, issued Jan. 19, 1988 to Vander Wielan et al. or any superabsorbent material such as described in U.S. Pat. No. 4,995,133, issuedFebruary 1991 and U.S. Pat. No. 5,638,569 both issued to Newell, U.S.Pat. No. 5,960,508, issued Oct. 5, 1999 to Holt et al., and U.S. Pat.No. 6,003,191, issued Dec. 21, 1999 to Sherry et al,

In one embodiment, the cleaning pad 28 may comprise a spunbond fibernonwoven web having a basis weight of approximately 68 grams per squaremeter. The spunbond fibers may comprise bicomponent fibers having aside-by-side configuration where each component comprises about 50%, byvolume, of the fiber. The spunbond fibers will comprise first and secondpolypropylene components and/or a first component comprisingpolypropylene and a second component comprising propylene-ethylenecopolymer. About 1% or more or less of titanium oxide or dioxide isadded to the fiber(s) in order to improve fiber opacity. The spunbondfiber nonwoven web thermally bonded with a point unbonded pattern. Thenonwoven web is bonded using both heat and compacting pressure byfeeding the nonwoven web through a nip formed by a pair ofcounter-rotating bonding rolls; the bonding rolls comprise one flat rolland one engraved roll. The bonded region of the nonwoven web comprises acontinuous pattern that corresponds to the pattern imparted to theengraved roll. Further, the bonded region is applied to the web when itpasses through the nip. The bonded region will range betweenapproximately about 27% to about 35% of the area of the nonwoven web andforms a repeating, non-random pattern of circular unbonded regions.Absorbency enhancing or superabsorbent materials, includingsuperabsorbent polymers, powders, fibers and the like may be combinedwith the cleaning pad 28.

Alternatively, the pad 28 comprises a laminate of an air-laid compositeand a spunbond fiber nonwoven web. The nonwoven web may comprisemonocomponent spunbond fibers of polypropylene having a basis weight ofapproximately 14 grams per square meter. The air-laid composite maycomprise from about 85% to about 90% kraft pulp fluff and from about 10%to about 15% bicomponent staple fibers. The bicomponent staple fibersmay have a sheath-core configuration; the core component comprisingpolyethylene terephthalate and the sheath component comprisingpolyethylene. The air-laid composite has a basis weight between about200 and about 350 grams per square meter and an absorbency of betweenabout 8 and about 11 grams per gram.

The cleaning pad 28 may also include a portion or side of hydrophilicfibers useful for scrubbing. Additionally, nylon fibers may be used toincrease the coefficient of friction when they become wet. Portions ofthe cleaning pad 28 may be composed of microfibers and ultra-microfibershaving a denier per filament (dpf) less than or equal to about 1.0.

As described, the cleaning pad 28 can be formed by any material ormaterial-forming process known, including woven and non-woven materials,polymers, gels, extruded materials, laminates, layered materials whichare bonded together integrally and thus form a co-material, fusedmaterials, extruded materials, air laying, etc.

The cleaning pad 28 may alternatively be optimized for providing acleaning fluid to the surface, such as with micro capsules orencapsulated fluids or agents. The enhanced surface of the cleaning pad28 can have scrubbing or abrasive qualities. The enhanced surface canalso be formed by a mechanical stamping, bonding, pressing, compression,extrusion, sprayed, sputtered, laminated or other surface forming oraffecting process. The various alternative cleaning solutions discussedabove could be microencapsulated into the cleaning pad such that theyare selectively released by some additional stimulus. It is understoodthat various cleaning solutions microencapsulated into the cleaning padcould be activated by water, another chemical in the fluid reservoir orpressure. The solutions could be dry impregnated. Alternatively, thechemical solutions could be encapsulated in pockets or bubbles on orwithin the pad 28 or on the cleaning media support 26. The pockets couldbe designed to burst and release the cleaning solution upon theapplication of moderate pressure.

It should be understood that the cleaning system 20 may be presentedwith its component parts partially preassembled or unassembled. Duringassembly or manufacture of the cleaning system 20, the ears 49 a, 49 bof the preformed handle portion 24 described above can be forced to flexoutward from each other as the pivot member 82 is inserted therebetweenin the orientation described above. The axles 80 a, 80 b slide along thepath defined by the grooves 52 a, 52 b , until they reach the pivot hole54 defined at the terminal end. Axles 80 a, 80 b fit within holes 54thereby defining a pivot joint. The sleeves 110 a, 110 b of the cleaningpad 28 are then placed over the attachment members 108 a, 108 b securingthe cleaning pad to the system.

The circular pivot member 82 accommodates rotational movement of thecleaning pad support member 26 in a range of about 55 to 65 degreesrelative to the longitudinal axis of the handle portion 24. Thepreferred range is ideal for accommodating the alternate fiber lengthsand cloth geometries of the inventive system. Particularly preferred isa range of about 61 degrees. When the cleaning pad support member 26 isfully extended in its cleaning position (FIG. 1), circular retentiontabs 95 fit within retention tab holes 87 and maintain the cleaning padsupport member 26 in its cleaning position.

FIGS. 1, 3, 4, and 10 illustrate the inventive cleaning system in itsalternating positions. FIG. 1 illustrates the cleaning system 20 in itscleaning position. As described above, in the cleaning position thecleaning pad support member 26 extends forwardly, pivot engagement tab38 engages the cleaning position notch 102 of pivot member 82, andretention tabs 95 fit within the retention tab holes 87 (FIG. 11). Theseengagement or retaining features create at least 2.5 lbf of pivot force.This amount of force is sufficient to maintain the cleaning pad supportmember 26 in its fully extending cleaning position despite any torqueexperienced during normal dusting, drying, or cleaning motions. Thus, inthe cleaning position, a user may manipulate the cleaning system 20 viathe handle portion 24. Additionally, the user may apply the water orother liquid housed within the fluid reservoir 30 directly onto thesurface to be cleaned. The user may insert a finger through the opening32 and depress the spray cap 61 thereby causing the discharge of thematerial housed within the reservoir 30. Due to the orientation of thecleaning system 20 in the cleaning position, the liquid or othermaterial (e.g. foam or powder) will typically be applied directly to thesurface to be cleaned in an area behind the cleaning pad 28 when thesystem is in a horizontal orientation such as when dusting a coffeetable. Alternatively, a cleaning solution can be sprayed onto a verticalsurface to be cleaned, such as a window or door molding.

FIGS. 4 and 10 illustrate the cleaning system 20 in a second liquidapplication position. In order to move the cleaning pad support member26 into the liquid application position, a user must hold the handleportion 24 and apply torque to the cleaning pad support member 26 tomove it from the cleaning position illustrated in FIG. 1. As sufficienttorque is applied to overcome the forces of the inventive engagementfeatures, the circular pivot member 82 rotates downwardly into theliquid application position. In the liquid application position, pivotengagement tab 38 engages the liquid application notch 104 of the pivotmember 82 thereby holding the cleaning pad support member 26 is itsangled liquid application state. In the illustrated embodiment, theangle Ø between the cleaning pad support member 26 and the handleportion 24 in the liquid application position may be between 45° and68°. Preferably, the angle Ø between the cleaning pad support member 26and the handle portion 24 is between 55° and 68° with 63° beingparticularly preferred. This preferred angle takes into considerationthe spray pattern of the fluid reservoir (shown in phantom) in order toachieve liquid application onto the greatest surface area of thecleaning surface 111 of the cleaning pad 28.

During dusting or cleaning a user may repeatedly rotate the cleaning padsupport member 26 from its cleaning position to its liquid applicationposition as needed. Alternatively, as noted above, a user may simplyapply liquid directly to the surface to be cleaned while using thecleaning system 20 in the cleaning position.

FIG. 3 illustrates the storage position of the cleaning system. Asillustrated in FIG. 3, in the storage position the cleaning pad supportmember 26 is rotated backwards such that it is generally parallel to theplane defined by the longitudinal axis of the handle portion 24. In thestorage position, engagement tab 3 8 engages the storage position notch106 thereby maintaining cleaning pad support member 26 in its foldedposition, In the storage position, the cleaning system 20 may be easilystored into a variety of spaces such as kitchen drawers or cabinets.Alternatively, the system can be hung on a wall using the opening 32 inthe handle portion 24.

As it can be appreciated from the description above the inventionincludes a novel method of adjusting the cleaning pad support member 26.One first obtains the cleaning system 20. While holding the handleportion (and preferably no other portion of the device), one presses thecleaning pad support member 26 against an object (e.g. a wall or afloor) to cause rotation of the cleaning support member 26 relative tothe handle portion 24. In an alternative embodiment, the pivot membermay include a torsion spring or other biasing means to return thecleaning support member 26 to its cleaning position without effort onbehalf of the user.

FIG. 10 illustrates an alternative embodiment of the cleaning pad 128 ofthe present invention. Cleaning pad 128 is similar to the pad previouslydescribed, however, pad 128 includes tapered fibers 129 on its cleaningsurface 111. As illustrated in FIG. 10, fibers 129 are tapered in amanner such that those fibers 129 closest to the handle portion 24 areshortest. As one moves away from the handle portion 24, the fibers 129become progressively longer in length. The tapered fiber length furtheraccommodates the cleaning system 20 in achieving a maximum cleaningfluid application surface area on the cleaning surface 111, in the fluidapplication position.

FIGS. 12 and 13 illustrate an additional alternative embodiment of thecleaning system. As illustrated by FIGS. 12 and 13, the cleaning fluidreservoir 30 of the previous embodiment has been replaced with aflexible pouch 130. In the alternative embodiment, spray nozzle or cap134, with an angled dip tube 140 may be retained in the handle portion24 as previously described. A user may puncture the seal at a preformedlocation 138 on the pouch with the pump dip tube 140. Alternatively, auser may screw the spray cap 134 onto a threaded pouch fitment 151 orthe spray cap 134 may be directly staked to the pouch 130 during thefilling operation. As illustrated in FIGS. 12 and 13, the cradle of theprevious embodiment has been replaced with a snap-fitting cover 142attached via a living hinge 141 to the handle portion 24. Cover 142secures the pouch 130 within the cleaning system 20.

b. Preferred Embodiments of the Cleaning Pad For Use With a CleaningSolution

FIGS. 14-39 illustrate preferred embodiments of the cleaning pad orcleaning article 28 that may be used with the inventive cleaning system22. In the illustrated preferred embodiments, the cleaning pad orcleaning article 28 is generally comprised of a cleaning fiber mat 203layered on one surface of a base sheet 202. The fiber mat 203 ispreferably bonded to the base sheet 202 in the lengthwise direction ofthe fiber mat 203 along a central bonding line 204 extendingcontinuously along the center of the base sheet 202. In addition, thefiber mat 203 is bonded to the base sheet 202 at spot bonding regions207 defining discontinuous lines that run parallel with the centralbonding line 204. Although the spot bonding regions 207 are illustratedin lines, they could be randomly orientated along the base sheet. Inaddition, as described below, the fiber mat could be bonded to the basesheet only by the spot bonding regions 207 and without the use of thecentral bonding line 204. As described in greater detail below, althoughthe size of the fibers defining the fiber mat 203 of the cleaning pad 28may vary depending on the application, it is preferable that the size ofthe fibers be between 1-18 denier.

Turning initially to FIGS. 14-16, a first preferred embodiment of thecleaning pad 28 of the present invention is illustrated. The cleaningpad 28 is formed by layering a fiber mat 203 on one surface of a basesheet 202. The base sheet 202 is preferably constructed from a nonwovensheet or other equivalent as is known in the art. The base sheet 202 andfibers 203 are preferably bonded together along a central bonding line204. In the illustrated embodiment, the central bonding line 204 extendsfrom a first base sheet edge 212 c to an opposed second base sheet edge212 d.

As illustrated in FIG. 15, in addition to the central bonding region204, the fiber mat 203 and the base sheet 202 are bonded at a pluralityof spot bonding regions 207. In one embodiment, the spot bonding regions207 generally define discontinuous parallel broken lines 205 a, 205 b,206 a and 206 b. In the illustrated embodiment, the broken lines 205 a,205 b, 206 a and 206 b are parallel to the central bonding line 204. Asdiscussed below, spot bonding regions 207 could also be randomlyorientated on the base sheet 202.

The cross sectional views illustrated in FIGS. 16 and 17, betterillustrate the bonding regions of fiber mat 203. The fibers of the fibermat 203 generally extend freely between the central bonding line 204 andthe edges 212 a, 212 b of the base sheet 202. However, portions of thefiber mat 203 are intermittently bonded to the base sheet 202 at theabove described spot bonding regions 207 (FIG. 16). Alternatively, FIG.17 illustrates a section of the fiber mat 203 that is not bonded at aspot bonding region 207 and extends freely from the central bonding line204 to the end of the fiber 231 a. Regardless of the orientation of thespot bonding regions 207, in the illustrated embodiments, the ends 231 aand 231 b of the fiber mat 203 are not bonded to the base sheet 202 andfreely extend. The cleaning pad 28 is thus designed so fibers of thefiber mat 203 are free to move along lengths ranging from either thecentral bonding line 204 or the spot bonding regions 207 to the ends 231a and 231 b. Due to this unique bonding pattern between the fiber mat203 and base sheet 202 (characterized by discontinuous spot-bondedregions 207 between the central bonding region 204) entanglements of theindividual fibers is lessened and the cloth exhibits an overall fluffierappearance. Furthermore, the configuration results in more open fiber inthe fiber mat 203.

As best illustrated in the embodiment shown in FIG. 15, the spot bondingregions 207 generally define lines 205 a, 205 b, 206 a and 206 b thatare parallel to the central bonding line 204. The individual spot bondedregions 207 are formed intermittently in a non-continuous linearfashion. The respective individual spot bonded regions 207 may be formedin a variety of shapes including circles, ellipses, ovals, straightlines, or the like. The spot bonded regions 207 may be formed such thatthe shapes of the spot bonded regions 207 are uniform, or,alternatively, the above shapes may be formed by a variety ofcombinations of the above shapes.

The width of the individual spot bonded regions 207 (along the lengthsof the fibers) is preferably between 0.5-5 mm, and the length (in thelengthwise direction of the center bonding region) is preferably 2-15mm. Each of the spot-bonded regions 207 is preferably spaced between5-50 mm apart. It is understood that the spacing between the individualspot bonding regions 207 may be uniform throughout the entire range ofthe spot bonding regions 207, or the spacing may vary in a variety ofpatterns.

In addition to the described orientation of the spot bonding regions207, the spot bonding regions 207 may be situated such that each of thespots alternates slightly to the left and right in the width-wisedirection of the base sheet 202 (lengthwise direction of the fibers)with the parallel line as the center, so that the spot bonded regions207 are positioned in zigzag patterns to the left and right with theparallel lines defining central lines. Thus, the spot bonding regions207 need not necessarily be lined up linearly above the parallel lines205 a, 205 b, 206 a, 206 b.

It should be understood, that the spot bonding regions 207 can beproduced in other configurations, and are not limited to the above notedconfiguration. For example, the spot bonded regions 207 may define oneparallel line between the central bonding line 204 and the edge 212 aand one parallel line between the central bonding line 204 and theopposed edge 212 b, so that they define only two parallel lines (e.g.,205 a and 205 b).

Alternatively, the spot bonded regions 207, could also define threeparallel lines between the central bonding line 204 and edges 212 a, 212b, such that they form a total of six parallel lines over the entirecleaning pad 28. Any number of lines could be formed, depending on theapplication.

The various spot bonding regions 207 do not overlap in the lengthwisedirection of the fibers of the fiber mat 203, and thus bonding atmultiple sites along the length of a single fiber does not occur. As aresult, the majority of the length of the fiber on the fiber mat 203 isfree. Because the fiber mat 203 is strategically unimpeded, thiseffectively prevents entanglement of the fibers of the fiber mat 203,while also allowing increased foreign matter trapping and retainingcapacity to be maintained over a longer period of time.

Although the fibers of the fiber mat 203 can take a variety of lengths,in the preferred embodiment, the lengths of the fibers from the centralbonding region 204 to the ends of the fibers in the lengthwise directionof the fibers is preferably 50-100% of the length from the centralbonding region 204 to the edges (212 a or 212 b) of the base sheet 202.In one preferred embodiment, a cleaning pad includes a base sheet 202with a width of 300 mm and a length of 200 mm. Preferably, the lengthfrom the central bonding region 204 to the edge of the base sheet 202 is100 mm, and the length of the fibers of the fiber mat 203 is preferablybetween 50-100 mm.

As illustrated in FIGS. 16 and 17, the fiber ends 231 a and 231 b in thelengthwise direction of the fibers of the fiber mat 203 are not bondedto the base sheet 202, and the length of the fiber that is allowed freemovement from the ends 231 a or 231 b of the fibers of the fiber mat 203to the bonded regions varies from about 10-40 mm from the spot bondedregions to about 50-100 mm from those fibers that are only bonded alongthe central bonding line. Preferably, the lines defined by thespot-bonded regions 207 are in the range of 10-40 mm from the edges (202a or 202 b) of the base sheet 202.

As noted above, the material of the base sheet 202 may be a non-wovencloth sheet, paper, synthetic resin sheet, or other known material. Inthe illustrated embodiment, the base sheet 202 is preferably a non-wovencloth sheet capable of trapping various types of foreign matter.Preferably, the nonwoven cloth used for the base sheet 202, weighsbetween 10 to 200 g/m² and has a thickness of between 0.01-0.1 mm.

In the preferred embodiment, when a thermal-welded fiber is used for thefiber mat 203, it is preferable for the base sheet 202 to have thermalwelding capacity conducive to bonding with the fiber mat 203. Likewise,when a nonwoven cloth sheet is used it is preferable that it bethermally weldable to the fiber mat 203. As noted above, examples ofsuch thermally weldable short fibers include polypropylene,polyethylene, polyethylene terephthalate and other fibers or materialsin which the fibers are present in a core-sheath structure or in aside-by-side structure, thus forming composite fibers.

The nonwoven cloth sheet that is used as the base sheet 202, may be aspunless nonwoven cloth, spunbonded nonwoven cloth, thermally bondednonwoven cloth, air-through bonded nonwoven cloth, spot-bonded nonwovencloth, or others. In the preferred embodiment, a spunless nonwoven clothor thermally bonded nonwoven cloth is utilized. The nonwoven cloth sheetmay be formed from a single sheet, or may be formed by the lamination ofmultiple sheets of the same or different types.

The fiber mat 203 used in the cleaning pad 28 may be produced byoverlaying multiple fibers so that they run in the same direction, ormay be formed from a fiber aggregate. The fiber mat 203 is preferably ina sheet-form. In addition, the fiber mat 203 can be partially bonded bymeans of welding or the likes between the various fibers. The fiber mat203 may include uniform fibers throughout, or may be constituted frommultiple types of fiber.

The fiber mat 203 may also be manufactured from fibers having the same,or multiple thicknesses. Likewise, the fiber mat 203 can be formed froman aggregate in which fibers of different color are used, regardless ofwhether the thicknesses and types of the constituent fibers are the sameor different.

As noted above, a wide variety of fibers may be used in the fiber mat203 including cotton, wool and other natural fibers, polyethylene,polypropylene, polyethylene terephthalate, nylon, polyacrylic and othersynthetic fibers, core/sheath fibers, sea-island type fibers,side-by-side fibers and other composite fibers. Synthetic fibers andcomposite fibers are preferred due to their thermal welding properties.In one preferred embodiment, the tow is a bi-component fiber consistingof a polypropylene core and a polyethylene outer surface or sheath. Thisis particularly preferred, because both materials have superior thermalwelding properties. In addition, the fibers used for the fiber mat 203may be formed from a crimped material produced by mechanical crimping orthermal crimping.

In one preferred embodiment, the fiber mat 203 may be a long fiber matgenerally referred to as “tow,” which is manufactured from polyethylene,polypropylene, nylon, polyester, rayon, or similar materials. Thethickness of the fibers that constitutes the fiber mat 203 is preferablybetween 1-18 denier. In addition, the weight of the fiber mat 203 ispreferably between 5-30 g/m² when the thickness of the fibers is about 2denier.

The cleaning pad 28 of the present invention can be obtained by layeringthe fiber mat 203 on the surface of the base sheet 202, and then bondingthe two along the central bonding line 204 and spot-bonded regions 207as previously described. This can be accomplished by thermal welding,ultrasonic welding, bonding, contact, or other known method.

In the preferred embodiments, the base sheet 202 and fiber mat 203 areformed from thermally weldable materials, and the laminate of the basesheet 202 and fiber mat 203 are heated and compressed with a hot roll tobond the two surfaces together. Alternatively, if the base sheet 202 orfiber mat 203 are not weldable, a thermally bondable material such ashot melt adhesive can be laminated between them, or bonding can becarried out by directly applying an adhesive between the two layers.

As discussed above, the fiber mat 203 or base sheet 202 may be coatedwith a chemical agent for improving foreign matter trapping performance,particularly of known allergens such as those disclosed in U.S. Pat, No.6,777,064. Examples of such chemical agents include liquid paraffin andother mineral oils, silicone oils and nonionic surfactants.

When the preferred cleaning pad is incorporated into the preferredcleaning system 22, the fiber mat 203 is laminated onto one side of thebase sheet 202 and bonded at a central bonding region 204. In addition,bonding is carried out at spot-bonded regions 207 formed discontinuouslyalong parallel lines between the two edges 212 a and 212 b parallel tothe center bonding region 204. Thus, a cleaning pad 28 is formed inwhich the two ends in the lengthwise direction of the fibers of thefiber mat 203 are not bonded to the base sheet 202.

As illustrated in FIGS. 18, 19 and 21 pockets or sleeves 110 of thecleaning pad 28 are formed by laminating and bonding a retaining sheet221 on the back surface of base sheet 202 (opposite the fiber mat 203),thereby forming a retaining opening 222 consisting of space whereby thearm of the attachment members 108 a, 108 b of the cleaning tool 22 canbe inserted and retained. In one embodiment, the retaining sheet 221 isbonded to the base sheet 202 along the central bonding line 204 and spotbonding regions 207 thereby defining two sleeves 110 a, 110 b. Theretaining sheet 221, need not be bonded along the same lines as thefiber mat, and may take a variety of configurations so long as itdefines a retaining opening 222.

As best illustrated in FIG. 18, base sheet 202 of the cleaning pad 28may also be provided with numerous cuts or fringes 225 that are cut inthe same direction as the lengthwise direction of the fibers of thefiber mat 203. The fringes 225 increase the surface area of the cleaningpad 28 and improve dust adhesion to the base sheet. As discussed below,a cleaning pad 28 may also be used without fringes along the base sheet202.

FIGS. 19-21 illustrate another preferred embodiment of the cleaning pad28 wherein the fiber mat 203 is formed by superimposing two or morefiber mats 203 a, 203 b constructed from different types of constituentfibers, different fiber sizes or different colors. Superimposing thevarious fiber mats provides for a cleaning pad 28 having differentproperties. In one preferred embodiment a fiber mat 203 a with thickerfibers alternates with a fiber mat 203 b of thinner fibers. For example,a fiber mat with a size of 0.01-0.05 mm is preferred in the thin mat 203a and a fiber mat with a size of 0.06 mm-0.3 mm is preferred for thethick mat 203 b. In addition, it is preferable to use a fiber with highstem strength such as polypropylene or nylon for the thick fiber mat 203b. The thick fiber mat 203 b is preferably constructed from bunchedfibers formed by splitting drawn polypropylene tape in the direction ofdrawing. The thick polypropylene fiber mat 203 b is preferably bondedonly at the central bonding line 204 to the preferred thin mat 203 bformed from bi-component tow fiber consisting of a polypropylene coreand a polyethylene outer surface. Thus, as illustrated in FIG. 21, thethick fiber mat 203 b hangs freely from the cleaning pad 28. As aresult, the fiber pad appears bulkier or fluffier.

The dual fiber mat 203 may be produced by laminating the thin sheet 203a to the base sheet 202 as described in reference to FIGS. 14-17. Thethick fiber mat 203 b is then layered over the thin fiber mat 203 a andbonded along the center bonding line 204.

Although the layering of alternative fibers in the fiber mat can becarried out in a variety of ways, in the illustrated embodiment thethick fibers 203 b are on the exterior (on the side of the surface to becleaned). This arrangement works particularly well for cleaning surfacesor appliances that include fine gaps such as a computer keyboard. Thethin fibers 203 a do not have body, and so they tend not to enter intothe gaps. In contrast, however, the thick fibers 203 b exhibit greaterstem strength, and as a result they more easily enter into the gaps,allowing dust, dirt and other foreign matter to be lifted off thesurface to be cleaned. In addition, thick fibers 203 b serve to prevententanglement of the narrow fibers and as well as provide a roughersurface to remove debris stuck to a surface.

In the illustrated embodiment, the length of the thick fiber mat 203 bin the lengthwise direction of the fibers is preferably somewhat shorterthan the length of the thin fiber mat 203 a, but the lengths may varydepending on the application.

FIGS. 22-24 illustrate another preferred embodiment of the cleaning pad28, or more particularly the retaining sheet. The retaining sheet 221 ofcleaning pad 28 is produced by laminating two sheets of nonwoven cloth221 a and 221 b, heat-sealing and bonding the center and three sides, todefine an insertion opening 223. A sack-form retaining part 222consisting of a space for inserting and retaining the attachment members108 a, 108 b is formed between the two non-woven cloths 221 a and 221 b.

As illustrated in FIG. 23, the insertion opening 223 of the retainingsheet 221 is formed. The retaining sheet 221 shown in FIG. 25 mayalternatively be produced by folding a single non-woven cloth in two,and heat sealing prescribed locations thereof, to create an insertionopening 223. The upper nonwoven cloth 221 a is formed so that it cancurve freely upwards at the edge of the sealed region 228 and thusfunctions as a border 229 that is not bonded to the nonwoven cloth 221 bunderneath.

In one preferred embodiment, a colored region or other indicia 224 maybe provided at the end of the border 229 indicating the orientation ofthe insertion region 223. Thus, when the upper nonwoven cloth 221a ismade longer than the lower nonwoven cloth 221 b and the border 29 isprovided, insertion of the attachment members 108 a, 108 b can becarried out easily and smoothly.

As an alternative to providing a colored part as the indicia 224 on theborder 229 of the retaining sheet 221, an embossing process can becarried out in order to provide a raised or lowered pattern at the samelocation, By providing indicia or on the insertion opening side 223 ofthe retaining sheet 22 1, the area where the attachment members 108 areto be inserted can be readily identified.

As illustrated in FIG. 24, the retaining sheet 221 is attached to thebase sheet by 202 by applying hot-melt adhesive 227 in the center of thebase sheet, and then laminating and heating the above retaining sheet221 and base sheet by a means such as heating or compression welding.Affixing the retaining sheet 221 to the cleaning pad 28 can be carriedout using adhesive or pressure-sensitive adhesive, as well as hot meltadhesive.

Attachment of the cleaning pad to the attachment members 110 is carriedout by inserting the attachment members 110 a, 110 b into the insertionopening 223 of the retaining sheet 221 so that it is retained in theretaining part 222. When the cleaning pad 28 becomes soiled, the armattachment members 110 are pulled out of the insertion opening 223 and afresh cleaning pad 28 is put in place.

Due to the combination of the bonding of the fiber mat 203 at a centralbonding region 204 as well as spot-bonded regions 207, and because theends of the fibers of the fiber mat 203 in the lengthwise direction arenot bonded to the base sheet 202, the fibers of the disclosed fiber mat203 are highly napped in comparison to prior art cleaning pads, allowingthe formation of a voluminous region of the fibers. This provides asignificant advantage over the less voluminous cloths of the prior art.Both ends in the lengthwise direction of the fiber mat 203 of the sheethang downwards, so that the tips of the fibers at both fiber ends arereleased from the base sheet and are free to move. As a result, thedisclosed fiber mat 203 has superior trapping performance and retentioncapacity with respect to dust, dirt and various types of foreign matterrelative to conventional sheets for cleaning implements in which longfiber filaments are cut and then napped at the surface or sandwichedbetween two carrier sheets.

FIGS. 25-39 illustrate additional preferred embodiments of the cleaningpad 28, configured to further increase the volume of free fibers of thefiber mat 203 in the cleaning pad 28, thereby increasing dust adhesionover prior art designs. It should be understood, that the variousfeatures of the cleaning pad 28 described in the different embodimentscan be combined in a variety of ways and none are mutually exclusive.For example the central bonding line 204 can be combined with the spots407 described below. Each embodiment includes a plurality of potentialalternative joining locations 440 that may include, for example spots407, or line sections 444. FIGS. 25-32 and 34-39 illustrate examples of“fringeless” base sheets 302, 402, 502, 602, 1002. Turning to FIG. 25,base sheet 402 may be constructed from a nonwoven or other knownmaterial as described above.

Base sheet 402 includes a uniform outer edge, such as a solid,unperforated, uncut outer edge 484. The outer edge 484 is defined by astraight, unperforated, uncut upper edge 460, a straight unperforated,uncut lower edge 462, and straight, unperforated, uncut side edges 464a, 464 b. Removal of the cuts or fringes 225 of the previous embodimenthas been shown to increase the fluffiness and total open fiber of thecleaning pad in comparison to a base sheet including the fringes. A basesheet 902 may also include an irregular or curved shape as illustratedin FIG. 32 without the fringes. It should be understood that thefringeless base sheet 402 may be used with the previous embodiments, andis no way limited to the embodiment shown in FIGS. 25-32. For example,FIGS. 30 and 31 illustrate the previously described cleaning pad 28 withthe fringeless base sheet 402.

FIG. 25 illustrates a first alternative bonding configuration. Asillustrated in FIG. 25, the cleaning pad includes a base sheet includinga plurality of joining locations or joining portions 440. The joininglocations 440 may include spot bonding regions 207 such as discretepoints, joining points, weldments or spots 407 for attachment of acombination of fibers or strips such as fiber bundle mat 203. Joininglocations 440 may also include the central bonding line 204 describedabove or the individual line sections 444 described below. Spots 407 arerandomly orientated along the base sheet 402 and illustrate potentiallocations for the nonwoven fibers to be attached as previouslydescribed. Although not shown in FIGS. 25-29, it is understood that thebase sheet 402 is configured for attachment of a fiber bundle mat 203 aspreviously described.

In the illustrated embodiment, the spots 407 are circular in shape. Itis understood, however, that the spots 407 could take a variety ofshapes. As illustrated in FIG. 27 spots or weldments 407 are triangularshaped. Numerous other configurations could be utilized as well,including, but not limited to, line portions, curved line portions,squares, rectangles, dashes and numerous other geometric shapes. Spots407 can be randomly orientated on the base sheet 407 or ordered in linesor other configurations. The number of spots can be altered to achieveoptimal open fiber and fluffiness in the fiber bundle mat 203 asdescribed in greater detail below.

FIG. 28 illustrates another embodiment of the base sheet 602. Asillustrated in FIG. 28, the base sheet 602 includes “star shaped” or“asterisk shaped spots” 607. Spots 607 include a central spot 609 with aplurality of line portions, for example, 611 a-d extending therefrom.The central spot 609 can also take a variety of alternative shapes, ascan the line portions 611 a-d.

As previously illustrated in FIGS. 18 and 20, a single central bondingline 204 could be added to a base sheet 202 with spot bonding regions207. As alternatively illustrated in FIG. 26, a discontinuous centralbonding line 406 may also be utilized. The discontinuous central bondingline 406 is comprised of a plurality of individual line sections 444. Itshould be understood that a plurality of discontinuous lines could beused.

FIG. 29 illustrates another embodiment of a base sheet 502. Base sheet502 is similar to those previously described, and can be fringeless orinclude fringes. Base sheet 502 includes a single curved or sinusoidalshaped bonding line 504 extending across the bonding surface 500 of thebase sheet. As illustrated in FIG. 28, the curved bonding line 504traverses across the base sheet 502 to provide a plurality of discretebonding locations e.g, 505 a-d. As illustrated by FIG. 28 the curvedbonding line 504 provides for an infinite number of discrete bondinglocations 505 a-d along different points of the curved line 504. Due tothe arcuate nature of the curved bonding line 504, many of the discretebonding locations, for example, 505 a-d along the curved line arelocated at unique positions along both the x and y axis of the basesheet 502 in comparison to other discrete bonding locations along thecurved bonding line 504.

It is understood that the curved bonding line 504 could take on avariety of alternative configurations other than that illustrated inFIG. 29 so long as it provides multiple bonding locations at uniquepositions along both the x and y axis of the base sheet 502 incomparison to other discrete bonding locations along the curved bondingline 504. In addition, multiple curved bonding lines 504 could beutilized.

Each of the above disclosed embodiments in FIGS. 18-32 provide asignificant advantage over known prior art cleaning pads, Specifically,the disclosed embodiments provide for a cleaning pad 28, with asubstantial increase in free fiber within the fiber mat 203 resulting inincreased fluffiness within the fiber mat 203 and greater dust adhesion.FIG. 33 illustrates one example of a portion of a prior art cleaning pad800. FIG. 33 illustrates a fiber bundle or fiber mat 807 bonded to abase sheet 802. As illustrated by the drawings, the individual fibers ofthe fiber mat 807 are bonded to the base sheet 802 at bonding lines 806a, 806 b. In addition, the fibers of the fiber mat 807 are bonded atjoining lines 810. This bonding architecture results in a tightly bondedfiber mat 807, with extremely minimal amounts of free fibers in thefiber mat 807. As a result the prior art cleaning pad 800 has a tendencyto push dust across a surface as opposed to retaining and absorbingdust.

In contrast, the disclosed embodiments of the cleaning pad 28 provide asignificant advantage over the prior art cleaning pads. For example, inthe illustrated embodiments, the fibers of the fiber mat 203 are bondedat one or more joining locations 440 such as spots 207 in a variety ofways to achieve a preferred amount of free fiber in the fiber mat 203.In one embodiment, 100% of the individual fibers of the fiber mat 203are connected to the nonwoven or base sheet 402 at one joining location440 such as spot 407 and between 5-90% of the fibers are connected attwo joining locations 440 such as spots 407. In another embodiment, 100%of the individual fibers of the fiber mat 203 are connected to thenonwoven or base sheet 402 at one spot 407 between 5-70% of the fibersare connected at at least two spots 407. In another alternative, 100% ofthe individual fibers are connected to the nonwoven sheet at one spotand less than 80% of the fibers are bonded at at least two spots.

A similar fiber open architecture can be achieved using a centralbonding line 204 and plurality of spots 407. For example, in oneembodiment, 100% of the fibers of the fiber mat 203 are connected to thenonwoven sheet at the central bonding line 204 and between 5-90% of thefibers of the fiber mat are bonded at at least one spot 407. In anotherpreferred embodiment, 100% of the fibers of the fiber mat 203 areconnected to the nonwoven sheet at the central bonding line 204 andbetween 5-70% of the fibers are connected at at least one spot 407. Instill another embodiment, 100% of the fibers of the fiber mat areconnected to the nonwoven sheet at the central bonding line 204, andless than 80% are connected at at least one spot 407.

The preferred open architecture can also be achieved by bonding thefiber mat 203 to the base sheet 402 using the discontinuous centralbonding line 406 illustrated in FIG. 26. In one preferred embodiment,between 10-90% of the fibers are connected to the discontinuous centralbonding line 406. In another embodiment, 80% of the fibers are bonded tothe discontinuous central bonding line 406.

As noted throughout the application, the previously described bondingconfigurations can be utilized to achieve a preferred amount of freefiber in the fiber mat 203. In the described preferred embodimentsillustrating a central bonding line 204 or discontinuous central bondingline 406, at least 80% of the total fiber bundle comprises fibers thatare free along at least 50% of their length from the central bondingline. Such fibers include fibers that are bonded only at a centralbonding line 204 or discontinuous central bonding line 406 as well asfibers that are bonded at a central bonding line 204 or discontinuouscentral bonding line 406 and at another bonding location less than onehalf of the length of the fiber from the central bonding line 204 ordiscontinuous central bonding line 406.

The architecture described above allows for the attachment of fiberbundle or fiber mat 203 such that a plurality of individual discretemicro channels is defined within the fiber bundle for retaining dust.For example, when the fiber mat or fiber bundle 203 is bonded to thebase sheet by a plurality of joining points or spots 407, a plurality ofdiscrete fiber clusters are produced. The individual fibers branchingfrom a single joining point or spot 407 define the fiber clusters. Microchannels are formed between the fibers of the fiber clusters. When thespots are randomly orientated, so too are the fiber clusters and microchannels. This is advantageous over the prior art illustrated in FIG.33, wherein the fiber clusters are uniformly formed.

FIGS. 34-39 illustrate another preferred embodiment of the cleaning pador cleaning article 28. The cleaning article illustrated is a“fringeless” cleaning article 1001. FIGS. 34-39 are directed toimproving the design of an existing cleaning pad by removing any fringesor cuts on portions of the cleaning pad and thereby providing a basesheet 1002 with an unperforated, uncut outer edge.

In FIGS. 34 and 35, a cleaning article or cleaning pad 1001 is shownwith its cleaning side upward. The cleaning article 1001 comprises auniform, unbroken outer edge, such as a fringeless unperforated, uncutprimary sheet (or base sheet) 1002, and a first fiber bundle layer 1003,a second fiber bundle layer 1004, a fringeless unperforated, uncutsecondary sheet 1005, and a third fiber bundle layer 1006 laminatedsubsequently upward on the cleaning face of the base sheet 1002. Theshorter sides of the cleaning article 1001 extend parallel to thefeeding direction (or MD) along which materials for the above-mentionedlayers are continuously fed on the production line. These individuallayers (i.e., the base sheet 1002, the first fiber bundle layer 1003,the second fiber bundle layer 1004, the secondary sheet 1005 and thethird fiber bundle layer 1006) are joined altogether at an all-layerjoining line 1007 extending perpendicularly to MD.

In the embodiment shown in FIGS. 34 and 35, the base sheet 1002 and thesecondary sheet 1005 are individually formed of a nonwoven fabric formedonly of or containing thermoplastic fibers (i.e., heat-fusible fibers).Examples of the thermoplastic fibers include: fibers of PE(polyethylene), PP (polypropylene) or PET (polyethylene terephthalate);and conjugated fibers of PE/PET or PE/PP (e.g., conjugated fibers of acore/sheath structure having a core of PP or PET and a sheath of PE).The nonwoven fabric may be a thermal bonded nonwoven fabric, aspun-bonded nonwoven fabric or a spun-laced nonwoven fabric.Alternatively, the base sheet 1002 and the secondary sheet 1005 may beformed of a thermoplastic resin film such as a PE film or a PP film. Ofcourse, it is also possible that the base sheet 1002 and the secondarysheet 1005 are formed of a laminated sheet of a nonwoven fabric and aresin film.

In order to increase the rigidity and elasticity, it is preferred thatthe base sheet 1002 and the secondary sheet 1005 are formed of athrough-air bonded nonwoven fabric in which the thermoplastic fibers arebonded with heated air. Especially where the secondary sheet 1005 isdisposed to form the outermost face of the cleaning article on thecleaning side it is desirable that the secondary sheet 1005 is formed ofa through-air bonded nonwoven fabric.

In the embodiment shown in FIGS. 34 and 35, the first fiber bundle layer1003, the second fiber bundle layer 1004 and the third fiber bundlelayer 1006 individually comprise a bundle of thermoplastic filaments.These individual filaments extend-continuously-to traverse each fiberbundle layer. Such a fiber bundle layer can be easily formed by openinga tow of filaments. More specifically, each fiber bundle layer can beformed over a sheet by the following steps of: opening a tow offilaments to have a predetermined width and a predetermined thickness(or bulk), while being fed continuously in MD; joining the opened towonto a continuously fed sheet material; and cutting the tow togetherwith the sheet material at an interval (corresponding to the size of thecleaning article in MD). The filaments may be made of any suitablematerials such as PE, PP, PET, Ne (nylon), rayon, or combinationthereof. Preferably, the filaments are conjugated fibers of acore/sheath structure having a core of PP or PET and a sheath of PE.

The filaments are preferred to have a fineness of 1 to 50 dtex, morepreferably 2 to 10 dtex. The individual fiber bundle layers may alsocontain fibers of different finenesses.

The fibers forming the fiber bundle layer of the invention should not belimited to the filaments. Flat yams or split yarns may also be employed.The flat yarns are prepared by slitting a film into tapes and bystretching the tapes in the longitudinal direction. The split yams areprepared by splitting a thermoplastic film in the directionperpendicular to the orientation direction of the resin so that the filmis fibrillated and interconnected into a net shape.

Preferably, the fibers forming the fiber bundle layer of the inventionare crimped. With the fibers being crimped, the fiber bundle layerbecomes so bulky as to take a structure enabled to capture dust easilyby the crimped portions. Especially preferred are crimped filamentsopened from a tow.

FIG. 37A shows the base sheet 1002 which is formed of a spun-bondednonwoven fabric, a through-air bonded nonwoven fabric, or the like. Thebase sheet 1002 includes an unperforated, uncut outer edge 1484. Theouter edge 1484 is defined by a straight, unperforated, uncut upper edge1460, a straight unperforated, uncut lower edge 1462, and straight,unperforated, uncut side edges 1464 a, 1464 b. Removal of the cuts orfringes 225 of the previous embodiment has been shown to increase thefluffiness and total open fiber of the cleaning pad in comparison to abase sheet including the fringes.

FIG. 36 shows the base sheet 1002 with its back face 1002B upward. Overthe back face 1002B, there is laid a holding sheet 1008. In theembodiment shown, the holding sheet 1008 is formed, like the base sheet1002, of a nonwoven fabric such as a spun-bonded nonwoven fabric, athrough-air bonded nonwoven fabric, or the like. The holding sheet 1008may also be formed of a resin film. The base sheet 1002 and the holdingsheet 1008 are identical in their sizes in MD, but not identical intheir sizes in the direction perpendicular to MD. The holding sheet 1008is shorter than the base sheet 1002 in the direction perpendicular toMD.

Over a cleaning face 1002A of the base sheet 1002 there is laid thefirst fiber bundle layer 1003. The individual filaments forming thefirst fiber bundle layer 1003 extend in MD, and the first fiber bundlelayer 1003 has a predetermined bulk over the cleaning face 1002A of thebase sheet 1002.

In such a laminated state, the base sheet 1002, the holding sheet 1008disposed on the outer face 1002B, and the first fiber bundle layer 1003disposed on the cleaning face 1002A are joined together at joining lines1013 and 1013 and joining lines 1014 and 1014. Here, the joining isperformed by heat-sealing, ultrasonic sealing or the like, so that thebase sheet 1002, holding sheet 1008 and the first fiber bundle layer1003 are fusion-bonded at the joining lines 1013 and 1014.

The paired joining lines 1013, 1013 extend parallel with one anotherwhile being spaced in MD. On the other hand, the joining lines 1014,1014 are formed in a zigzag shape near the straight, unperforated, uncutupper edge 1460 and straight unperforated, uncut lower edge 1462.

As a result, as shown in FIG. 35 in an enlarged scale, the individualfilaments forming the first fiber bundle layer 1003 are joined to thebase sheet 1002 at the joining lines 1014 extending obliquelytransversely over the base sheet 1002. With the joining lines 1014,motions of the individual filaments can be restrained so that thefilaments are prevented from being excessively separated or entangled,while being enabled to move over the base sheet 1002 relatively freely.

FIG. 38 shows the state in which the second fiber bundle layer 1004 andthe secondary sheet 1005 are laminated. The secondary sheet 1005 isformed of a spun-bonded or through-air bonded nonwoven fabric, like thebase sheet 1002, or a resin film. The secondary sheet 1005 has the samesize and shape as those of the base sheet 1002.

The second fiber bundle layer 1004 is laminated on the back face 1005Bof the secondary sheet 1005. In the manufacture process, the back face1005B of the secondary sheet 1005 is directed upward, and the secondfiber bundle layer 1004 is laid over the back face 1005B. At this time,the individual filaments forming the second fiber bundle layer 1004extend in MD, and the second fiber bundle layer 1004 has a predeterminedbulk over the back face 1005B of the secondary sheet 1005.

In such a laminated state, the secondary sheet 1005 and the second fiberbundle layer 1004 are joined together at joining portions 1018. At thesejoining portions 1018, specifically, the secondary sheet 1005 and thesecond fiber bundle layer 1004 are fusion-bonded by heat-sealing orultrasonic sealing.

As shown in a partially enlarged view of FIG. 35, the second fiberbundle layer 1004 is joined to the secondary sheet 1005 at the joiningportions 1018. Therefore, the second fiber bundle layer 1004 is retainedin its shape by the secondary sheet 1005 so that the filaments formingthe second fiber bundle layer 1004 are prevented from being excessivelyentangled or curled.

At the final stage of the manufacture process of the cleaning article1001, over the first laminate in which the base sheet 1002, the holdingsheet 1008 and the first fiber bundle layer 1003 are laminated andjoined, as shown in FIG. 37B, there is laid the second laminate in whichthe second fiber bundle layer 1004 and the sheet 1005 are laminated andjoined, as shown in FIG. 38. At this lamination, the first and secondlaminates are laid such that the second fiber bundle layer 1004 liesover the first fiber bundle layer 1003.

As illustrated in FIG. 37A, over the cleaning face of the secondarysheet 1005 of the second laminate, there is laid the third fiber bundlelayer 1006, as shown in FIG. 34. The individual filaments forming thethird fiber bundle layer 1006 extend in MD, and the third fiber bundlelayer 1006 has a substantially homogeneous bulk over the cleaning face1005A of the secondary sheet 1005. Then, the holding sheet 1008, thebase sheet 1002, the first fiber bundle layer 1003, the second fiberbundle layer 1004, the secondary sheet 1005 and the third fiber bundlelayer 1006 are joined altogether into an integral structure at theall-layer joining line 1007 which extends in MD along the center line ofthe cleaning article 1001. This all-layer joining line 1007 is a fusingseal line by heat sealing, ultrasonic sealing or the like, so that theindividual layers are fusion-bonded at the all-layer joining line 1007to be integrated altogether.

As shown in FIGS. 34 and 35, the cleaning article 1001 thus constructedhas brush portions 1026 at right and left sides on the cleaning face1002A of the base sheet 1002. These brush portions 1026 are formed bythe edge of the base sheet 1002, the first fiber bundle layer 1003, thesecond fiber bundle layer 1004, the edge of the secondary sheet 1005 andthe third fiber bundle layer 1006.

When the floor, furniture, or the like is wiped with the cleaning sideof the cleaning article 1001, which is shown upward in FIG. 34, finedust can be collected by the third fiber bundle layer 1006 appearing onthe outermost face of the cleaning article 1001, and by the first andsecond fiber bundle layers 1003 and 1004 inside of the brush portions1026. Here, the edges of the sheets exhibit the function to wipe off thedust, and the dust, can also be trapped by the fiber bundle layers 1003,1004 and 1006.

In this embodiment, the secondary sheet 1005 is interposed between thesecond fiber bundle layer 1004 and the third fiber bundle layer 1006.When the cleaning operations are repeated, therefore, the filaments ofthe second fiber bundle layer 1004 and the filaments of the third fiberbundle layer 1006 are prevented from being excessively entangled, sothat the shape of the brush portions 1026 can be retained for a longterm.

Moreover, the filaments of the first fiber bundle layer 1003 and thefilaments of the second fiber bundle layer 1004 are partially joined tothe secondary sheet 1005, so that they are prevented from beingexcessively curled or entangled. Even after use in a cleaning operationfor a long period, the brush portions 1026 retain their shape.

On the outer face side of the cleaning article 1001 thus completed, asshown in FIG. 36, the base sheet 1002 and the holding sheet 1008, whichare firstly joined at the joining lines 1013 and 1013, are furtherjoined at the all-layer joining line 1017 which is formed midway betweenthe joining lines 1013 and 1013. In the holding region on the outer faceof the central region therefore, there are formed two parallel holdingspaces 1020 and 1020, each of which is defined between one of thejoining lines 1013 and the all-layer joining line 1007. Therefore, thecleaning article 1001 can be held from the outer face side by a handleportion or holder 24. An alternative holder 1021 of a bifurcatedstructure, is shown in FIG. 36. This holder 1021 includes bifurcatedinsert portions 1022 and 1022 and a grip portion 1023. The insertportions 1022 and 1022 are inserted into the holding spaces 1020 and1020. Thus, the cleaning operation can be performed by holding the gripportion 1023.

It is possible to adopt a variety of structures for preventing thecleaning article 1001 from easily coming out of the holder 1021 at thecleaning time. First, the insert portions 1022 and 1022 may be formed ontheir lower faces with a number of saw-tooth shaped protrusions 1022 a,which are arranged finely with sharp edges. With the protrusions 1022 abeing directed toward the base sheet 1002, the insert portions 1022 and1022 are inserted into the holding spaces 1020 and 1020. In thisinserted state, the saw-tooth shaped protrusions 1022 a and the basesheet 1002 are retained in a high coefficient of friction so that theycan prevent the cleaning article 1001 from easily coming out.

It is also effective to fix a retaining fastener 1024 on the root endportion of the insert portions 1022 and 1022 of the holder 1021. Thisretaining fastener 1024 is formed with fine hook-shaped ormushroom-shaped projections. With the retaining fastener 1024 beingretained on the back face 1002B of the base sheet 1002, the cleaningarticle 1001 is prevented from coming out of the holder 1021.

Moreover, it is also possible to provide a pivotable connect member 1025to the leading end portion of one of the bifurcated insert portions1022. This connect member 1025 is turned, when the insert portions 1022and 1022 are inserted so far into the holding spaces 1020 and 1020 thattheir leading ends pass through and come out of the holding spaces 1020and 1020, to thereby retain the connect member 1025 on the leading endof the other insert portion 1022 by engagement between concave andconvex, or the like. The prevention of the cleaning article 1001 fromcoming out of the holder 1021 can also be ensured by this retention.

To the holder 1021, there may be provided all or at least one of themeans for preventing the coming-out of the cleaning article 1001 (i.e.,all or at least one of the protrusions 1022 a, the retaining fastener1024 and the connect member 1025). Here, the holder 1021 having suchmeans can be used not only in the cleaning article of the invention butalso in any cleaning article.

The cleaning article 1001 thus far described has a symmetrical shape, asshown in FIG. 36. Therefore, if the cleaning article 1001 is used forcleaning operation while being attached to the holder 1021 from thedirection shown in FIG. 36 and is locally soiled, the cleaning article1001 may be removed from the holder 1021 and turned 180 degrees from theposition shown in FIG. 36 to be attached to the holder 1021 again. Ifthe cleaning article 1001 is used for cleaning operation by changing itsdirection thus described above, the individual portions of the cleaningarticle 1001 can be homogeneously used without any unbalance.

If the insert portions 1022 of the holder 1021 are formed of an easilydeformable material, it is possible to arbitrarily bend the shape of thecleaning article 1001 held by the holder 1021. If the grip portion 1023is given an extensible structure, on the other hand, the cleaningoperation may be performed while the grip portion 1023 being extended.

Here in the cleaning article 1001, the first fiber bundle layer 1003 isjoined to the base sheet 1002 at the joining lines 1013 and 1013, asshown in FIG. 1004B, so that the cleaning faces of the insertionportions 1022 and 1022 to be inserted into the holding spaces 1020 and1020 are covered at any time not only with the base sheet 1002 but alsowith the first-fiber bundle layer 1003. Therefore, even if the right orleft brush portion is unintentionally turned over during cleaningoperation, the first fiber bundle layer 1003 exists at a predeterminedsufficient thickness between the object to-be cleaned and the insertionportions 1022 and 1022 of the holder 1021. As a result, the object to becleaned is not affected by the hardness of the holder so that thecleaning article 1001 provides a smooth contact feel when used forcleaning operation.

FIG. 39 is a perspective view showing a cleaning article 1001A as amodification of the first embodiment of the invention. The cleaningarticle 1001A shown in FIG. 39 is prepared by changing the order oflaminations of the individual layers of the cleaning article 1001 shownin FIGS. 34 to 38.

In this cleaning article 1001A, there is provided an outermost basesheet 1015 which is formed of a through-air bonded nonwoven fabric, andthe base sheet 1002 formed of a spun-bonded nonwoven fabric or the likeis laid over the cleaning face of the this outermost base sheet 1015.Over the cleaning face 1002A of the base sheet 1002, moreover, there arelaid the first fiber bundle layer 1003, the second fiber bundle layer1004, the third fiber bundle layer 1006 and the sheet 1005 sequentiallyupward. The secondary sheet 1005 is again formed without any strips orcuts and appears on the outermost face of the cleaning article 1001A onits cleaning side. The secondary sheet 1005 may be formed of anysuitable material such as a nonwoven fabric or a resin film, but ispreferably formed of a through-air bonded nonwoven fabric.

Then, the outermost base sheet 1015, the base sheet 1002 and the firstfiber bundle layer 1003 are joined to one another on the same joininglines 1013 and 1013 as those shown in FIG. 37B. Moreover, all the layersfrom the outermost base sheet 1015 to the sheet 1005 having the strips1017 are joined altogether at the same all-layer joining line 1007 asthat shown in FIGS. 34 and 35. This all-layer joining line 1007 extendsalong the center line of the cleaning article 1001A.

Here, as in the structure shown in FIG. 38, the third fiber bundle layer1006 and the overlying sheet 1005 may be joined at the joining lines1018.

Of course, it is also possible that the holding sheet 1008 is joined tothe outer face of the outermost base sheet 1015, as in FIG. 36, to formthe holding spaces 1020 and 1020 between the outermost base sheet 1015and the holding sheet 1008.

In the cleaning article 1001A shown in FIG. 39, the sheet 1005 isprovided to form the outermost face on the cleaning side so that itabuts preferentially against the object to be cleaned, such as floor,furniture or the like. Therefore, it is possible to prevent thefilaments of the individual underlying fiber bundle layers 1003, 1004and 1006 from being excessively entangled or massed by the friction withthe object to be cleaned. Especially if some of the filaments of thethird fiber bundle layer 1006 are joined at the joining lines 1018, theyare hardly entangled or massed. If the outermost secondary sheet 1005 isformed of a highly rigid and soft through-air bonded nonwoven fabric,moreover, the brush portions 1026, as formed of the strips and the fiberbundle layers, are hardly deformed by the friction with the object to becleaned, so that they hardly lose their shapes even after being used fora long term.

In the cleaning article 1 shown in FIGS. 34 to 39, therefore, it ispreferred to apply a fixing agent to the third fiber bundle layer 1006appearing on the outermost face. Examples of the fixing agent include anoil agent, a wax, and a resin such as a HMA (hot melt adhesive). Thisfixing agent thus applied can prevent freedom of movement of thefilaments (i.e., suppress disaggregation of the filaments) so that thefilaments can be prevented from being excessively entangled or massed atthe wiping time.

This fixing agent may be partially applied to the third fiber bundlelayer 1006. For example, the fixing agent may be sprayed exclusively tothe cleaning face of the third fiber bundle layer 1006 thereby to fixthe filaments appearing on the cleaning face of the third fiber bundlelayer 1006 exclusively. Alternatively, the fixing agent may be appliedto the third fiber bundle layer 1006 over a predetermined length fromthe all-layer joining line 1007 so that the filaments forming the thirdfiber bundle layer 1006 remain free on the side of their free ends. Inboth cases, the filaments forming the third fiber bundle layer 1006 canbe prevented from being excessively entangled without lowering the dusttrapping effect by the fiber bundle layer 1006. Preferably, the fixingagent is solid at room temperature.

In the case where a wax is used for fixing, for example, the ratio ofthe wax to the fiber bundle layer 1006 is preferably from 0.5 to 25% byweight. If the ratio is less than 0.5% by weight, the entanglement ofthe filaments could not be prevented effectively. If more than 25% byweight, on the other hand, the filaments will be excessively firmlyfixed. Therefore, since the filaments can not be sufficiently raised,the dust trapping effect is lowered.

In the case where a HMA is used for fixing, a HMA with a low viscosityis preferred. If a MA having a high viscosity is used, dust trappingproperty is enhanced but the filaments are liable to be entangled. Ofcourse, the fixing agent may be prepared by mixing a wax and a HMAhaving a low viscosity.

Here, the entanglement of the filaments may be prevented not by themethod of applying the fixing agent to the fiber bundle layer 1006 butby solidifying the filaments of the fiber bundle layer 1006 again aftermelting them with a solvent or by a heat. In this case, too, it ispossible to firmly fix the filaments of the fiber bundle layer 1006 onlyat the side of the all-layer joining line 1007 to prevent theentanglement, while leaving the degree of freedom at the side of theirleading ends so that the filament can be raised easily.

Of course, the fixing of filaments in each fiber bundle layer should notbe limited to the cleaning article 1001. For example, also in thecleaning article 1001A shown in FIG. 39, the filaments in the individualfiber bundle layers 1004 and 1006 may be fixed to one another with afixing agent or by fusing them, as has been described above.

In the cleaning article 1001 shown in FIG. 34, the third fiber bundlelayer 1006 is joined to the other layers only at the all-layer joiningline 1007. However, it is also possible to form other joining linesspaced apart from the all-layer joining line 1007 to thereby join thethird fiber bundle layer 1006 only to the underlying sheet 1005 or toall the other layers (i.e., from the sheet 1005 to the base sheet 1002).This can also prevent the filaments of the third fiber bundle layer 1006from being excessively entangled or massed.

In both the cleaning article 1001 shown in FIG. 34 and the cleaningarticle 1001A shown in FIG. 39, it is preferable that the basis weightof the first fiber bundle layer 1003 closest to the base sheet 1002 islarger than those of the overlying second fiber bundle layer 1004 andthird fiber bundle layer 1006.

In the foregoing individual embodiments, if the fiber bundle layers areformed of crimped fibers, the fibers themselves can trap the dusteasily. If the fibers (e.g., filaments opened from a tow or split yams)are joined to the sheet while being stretched in MD, and are then cuttogether with the sheet, moreover, the fibers are crimped so that theportions of the fiber bundle layer forming the brush portions becomeshorter than the strips. In this construction, it is possible to enhanceboth the dust trapping function by the crimped fibers and the dustwiping function by the strips extending beyond the free ends of thecrimped fibers, so that the cleaning function can be effectivelyexhibited by the assembly of the fibers and the strips.

Moreover, the dust adsorbing and trapping effect can be enhanced byapplying a dust-adsorbing agent to the fiber bundle layers and/or thestrips. This dust-adsorbing agent is exemplified by a surface-activeagent, mineral oil or wax. It is also possible to apply an acrylicadhesive or a hot melt adhesive which has a weakened adhesion.

The fiber bundle layers may further contain a substance such as adeodorant, a humectant or an anti-fungus agent in addition to thedust-adsorbing agent.

If the sheets in the individual embodiments are given an elasticstretchability between the joining lines formed in the holding region,moreover, the sheets can make close contact with the holder when thecleaning article is attached to the holder, so that the cleaning articlehardly comes out of the holder.

In the individual embodiments, the nonwoven fabric to be used to formthe sheets should not be limited to one formed by the spun-bondingprocess or the through-air bonding process, but may be formed by thethermal bonding, spun-lacing, point-bonding, melt-blowing, stitchbonding, chemical bonding, needle punching or the like. Moreover, thenonwoven fabric may be replaced by a material such as urethane, sponge,a woven fabric, a net or a split cloth.

Where the sheets are formed of a nonwoven fabric, the nonwoven fabric ispreferred to have a basis weight of 10 to 100 g/m² and a thickness of0.5 to 5 mm, from the point of view of handleability when combined withthe fiber bundle layers and from the point of view of processingtechnique. Moreover, the nonwoven fabric is preferred to have a width of80 to 250 mm in MD.

The above-described preferred embodiments of the cleaning pads orcleaning articles 28 are particularly well suited for the inventivesystem 20 that is capable of either wet, damp or dry cleaning ordusting. Known prior art cleaning pads and more particularly dustingpads have been hydrophobic. As a result, the prior art cleaning pads arenot capable of using the inventive advantages of the use of low levelsof a liquid product.

The present cleaning pad allows for an inventive wet damp or dry dustingmethod. In particular, the inventive system 20 uses a low level ofliquid product combined with a dry dusting or cleaning pad 28 toincrease dust removal. In the preferred embodiment the liquid level usedis between 0.01 to 0.3 g/sq.ft. Alternatively, the preferred liquidlevel applied to the cleaning pad is between 80 and 500 microliters.Particularly preferred is a range of between 120 to 130 microliters. Asdescribed throughout the application the liquid could be water, solventor emulsion based intermediates.

c. Methods of Use and Methods of Cleaning

It should be appreciated from the above disclosure that the preferredcleaning tool 22, can be utilized to clean or dust a variety ofsurfaces. Due to the unique configuration of the tool 22, a user canconveniently alternate between wet, damp or dry cleaning or dusting. Itis recognized that the component parts of the invention may beconveniently interchanged depending on the particular cleaning task athand. For example, some of the disclosed cleaning pads 28 may be moresuitable for use with some of the disclosed cleaning solutions or fordry dusting. Likewise, some cleaning pads 28 may include alternatesurfaces configured for alternative cleaning tasks. Similarly, theparticular cleaning solution utilized can be changed depending on thedesired application.

In order to perform dry dusting, a user may obtain the above mentionedcleaning system 20 that includes the preferred cleaning tool 22. A userholds the cleaning tool 22 such that the palm of the user's handsurrounds the handle portion 24. In the preferred embodiment, the palmof a user's hand extends over the top 29 of the handle portion 24 andthe user's fingers extend at least partially around the fluid reservoir30. However, it is recognized that in performing dry dusting tasks, thefluid reservoir 30 need not be present. In the illustrated embodiment, auser's hand is typically orientated in a manner such that a user mayinsert his or her index finger through the hole 32 extending throughhandle portion 24.

Once the user obtains the tool 22, a user then places the cleaning pad28 onto the cleaning pad support member 26. As noted above, the cleaningtool may be used with a variety of alternative cleaning pads 28. In thepreferred embodiment, the sleeve-like cleaning pad 28 is mounted overthe attachment members 108 a, 108 b so that all of the retaining tabs112 are within the sleeves 110 a, 110 b. Once secured, the user thenpositions the cleaning pad 28 onto a surface to be cleaned and moves thecleaning pad 28 on the surface to be cleaned. The movement of thecleaning pad 28 across the surface to be cleaned causes dust or otherdebris to be collected by the cleaning pad 28. In the illustratedembodiment, dust or other debris is collected by the cleaning surface111 of the cleaning pad 28. The user may, depending on the surface to becleaned, pivot the cleaning pad support member 28 to accommodate hard toreach places. For example, if a user desires to dust an overhead lintel,the user may pivot the cleaning pad support member 26 to an angle ofabout 90° in relation to the handle portion 24.

A preferred dusting or cleaning pattern consists of a side to sideoverlapping motion starting in the upper left hand (or right hand) sideof the section to be cleaned, and progressing the wiping pattern acrossthe surface to be cleaned while continuing to use side to side wipingmotions. Another preferred wipe pattern consists of an up-and-downwiping motion. The preferred wiping patterns allow the cleaning pad 28to loosen dirt and dust, and provide a better end result. Anotherbenefit of the above wiping patterns is minimization of streaks as aresult of improved spreading of solution (in wet dusting).

It is recognized that wet dusting or cleaning can be done separatelyfrom, in conjunction with or in addition to dry dusting. For example, auser may perform an initial dry dusting run and then proceed with wetdusting or cleaning. In the context of wet cleaning or dusting, similarsteps are performed to those described above in the context of drydusting. However, if necessary, the cleaning fluid reservoir 30 isinitially inserted into the fluid reservoir-receiving cradle 36. Thefluid reservoir 30 is inserted between the handle portion sidewalls 21a, 21 b and within the two U-shaped supports or rails 44 and 46. Thefluid reservoir 30 is press fit into the cradle such that the triangularretention tabs 42 a, 42 b frictionally engage and retain the lowersidewall 53 of the fluid reservoir 30. The reservoir should be press fitsuch that the first bottleneck receiving support 44 fits around thefluid reservoir 30 near the junction 59 of the second 55 and third 57sections of the reservoir 30. The second U-shaped spray cap receivingsupport 46 fits around, retains and orientates the spray cap 61 of thefluid reservoir 30. The spray cap receiving support flanges 71 a, 71 bpress fit around flats 63 a, 63 b of fluid reservoir spray cap 61 whenthe reservoir is placed within the cradle 36. The tight fit defined byflanges 71 a, 71 b and flats 63 a, 63 b serves to properly orientatespray cap 61 within the fluid reservoir-receiving cradle 36 such thatspray cap 61 faces in a direction away from the cradle 36.

During wet dusting or cleaning, a variety of techniques may be employedconsisting of combinations of wetting the surface and moving thecleaning pad 28 across the surface to be cleaned, wetting the cleaningpad 28 and moving the cleaning pad 28 across the surface to be cleaned,or a combination of the two.

FIG. 1 illustrates the cleaning system 20 in its cleaning position thatis configured for wet cleaning wherein the cleaning solution is applieddirectly to the surface. As described above, in the cleaning positionthe cleaning pad support member 26 extends forwardly, pivot engagementtab 38 engages the cleaning position notch 102 of pivot member 82, andretention tabs 95 fit within the retention tab holes 87. In thisposition, the user may apply the water or other liquid housed within thefluid reservoir 30 directly onto the surface to be cleaned. The user mayinsert a finger through the opening 32 and depress the spray cap 61thereby causing the discharge of the fluid housed within the reservoir30.

FIG. 4 illustrates the cleaning system 20 in a second liquid applicationposition. In order to move the cleaning pad support member 26 into thesecond liquid application position a user holds the handle portion 24and applies torque to the cleaning pad support member 26 to move it fromthe cleaning position illustrated in FIG. 1. As sufficient torque isapplied to overcome the forces of the inventive engagement features, thecircular pivot member 82 rotates downwardly into the liquid applicationposition In the second liquid application position, pivot engagement tab38 engages the liquid application notch 104 of the pivot member 82thereby holding the cleaning pad support member 26 in its angled liquidapplication state. In this position, the user may apply the water orother liquid housed within the fluid reservoir 30 directly onto thecleaning surface 111 of the cleaning pad 28. As noted above, the variouscleaning positions may be used interchangeably. During dusting orcleaning a user may repeatedly rotate the cleaning pad support member 26from its cleaning position to its liquid application position as needed.During wet dusting or cleaning, the user may use the above notedcleaning pattern.

Once the cleaning or dusting has been finished, the user may remove anddispose of the cleaning pad 28 and place the cleaning system 22 into itsstorage position (FIG. 3). To place the cleaning system 22 into thestorage position, the cleaning pad support member 26 is rotatedbackwards such that it is generally parallel to the plane defined by thelongitudinal axis of the handle portion 24.

As noted above, a variety of cleaning solutions can be used with theinventive cleaning system. In one preferred method of light cleaning ordusting, the cleaning solution is a mixed liquid that includes about96.30% by weight tap water, 1% isoparaffinic hydrocarbon solvent, suchas Isopar E from Exxon Mobil, 1% silicone fluid, preferably 1000 estkspolydimethyl siloxane silicone oil from Dow Corning, General ElectricSilicones or Rodia Chemical, 0.5% sorbitan monolaurate, 0.5%polyoxyethylene (20) sorbitan monolaurate or other emulsifier, and aquaternary such as 0.15% BTC 2125M from Stepen Chemicals. The balance ofthe preferred solution includes a fragrance and preservatives. Thiscomposition is ideally suited for dusting jobs. Use of the preferredsolution with the inventive cleaning system provides an increase in dustand allergen retention as well as providing an improved shine to thesurface to be cleaned. Fingerprints, smudges and other blemishes arealso easily removed.

In another preferred embodiment a cleaning solution includes 96.5125% byweight deionized water, 1.75% propan-2-ol anhydrous, 0.40% ethyleneglycol monobutyl ether, 0.40% ethylene glycol n-hexyl ether, 0.125%propylene glycol, 0.10% monoethanolamine, 0.30% vinegar (white distilled300 grain), and small amounts surfactants and other ingredients.

In another preferred embodiment the cleaning solution includes 97%de-ionized water, 1.50% anhydrous propan-2-ol, 0.30% ethylene glycolN-hexyl ether, 0.13% industrial grade propylene glycol, 0.08% of asurfactant 0.30% Mackam, 0.10% monoethanolamine, and small amountssurfactants and other ingredients.

In still another preferred embodiment the cleaning solution includes91.8% de-ionized water, 5.0% isoparaffinic hydrocarbon, 0.25% elfuginAKT, 0.15% sodium n-cocoyl sarcosinate, 2.0% silicone fluid, 0.15%sorbiatnmono oleate, 0.15% polyoxyethylene sorbitan monolaurate, 0.1 5%low freeze grade triethanolamine, 0.15% formeldahyde and small amountsof other ingredients.

In another embodiment, the cleaning solution includes 92.32% de-ionizedwater, 5% isoparafinnic hydrocarbon, 2% silicone fluid, 0.15% sorbianmono oleate, 0.15% polyoxyethylene sorbitan monolaurate, 0.03%triethanolamine, 0.15% formaldehyde and small amounts of otheringredients.

It can be important to control dosing and coverage of the cleaningsolution. In one preferred embodiment, the liquid level that should beused with the preferred cleaning pad via application to the cleaningsurface is between 0.01 to 0.3 g/sq.ft. Alternatively, the preferredliquid level applied directly to the cleaning pad is between 80 and 500microliters. Particularly preferred is a range of between 120 to 130microliters. For best results, the product is applied at theabove-recommended doses, onto the surface to be treated or onto thecleaning pad 28 and the cleaning pad 28 is then moved across the surfacecollecting dust and absorbing the cleaning solution if applied directlyto the cleaning surface. Instructions for use of the cleaning system mayinclude pictures and/or words detailing preferred application patternand dosing. As noted above, the preferred composition of this inventionis mild and minimizes harm to most surfaces.

As noted above, in the context of wet dusting, the cleaning solution canbe distributed using the fluid reservoir 30. Optionally, for increasedconvenience, additional compositions can be delivered in the form of apre-moistened cleaning pad 28.

Optionally, and most preferably, convenience and performance can bemaximized by using a system composed of a disposable cleaning pad 28 asdescribed hereinbefore. The pad can be composed of any one of thealternative cleaning pads 28 described above.

This cleaning system 22 and method of use provides multiple benefitsversus conventional cleaning modes. It reduces time to clean or dustbecause the cleaning pad retains a greater amount of dust and thepreferred cleaning solution removes fingerprints smudges and othersurface marks. It eliminates the need to carry a separate dusting orcleaning solution. Due to the high absorbency of the pad, especiallywhen used in conjunction with the preferred cleaning solution, the padabsorbs and locks away dirt and dust, such that a single pad 28 canclean large surface areas.

Additionally, since a fresh pad 28 may be used every time, germs anddirt are trapped, removed and thrown away, promoting better hygiene.Conventional dusting tools, which are re-usable, can harbor dirt andgerms, which can be spread throughout the household. Throughoperator-controlled dosing and more efficient removal of dirt and dust,a better end result is also achieved.

Additionally, because the cleaning process involves use of low levels ofsolution in contact with the surface to be cleaned for much shorterperiods of time relative to conventional cleaning systems, (e.g. themultiple steps of applying a separate cleaning solution and grabbing acleaning tool are combined in the present invention), the system andmethod provide improved surface safety on delicate surfaces.

The cleaning pads 28 are versatile in that they can be used for multiplecleanings and multiple surfaces. Each pad is designed to clean at leastone average size surface with an average debris or dust load. Pads canbe changed sooner if surfaces are larger than average, or especiallydirty. To determine if the pad needs changing, look at the back of thecleaning surface of the cleaning pad and ascertain if the cleaningsurface is saturated with dust and/or dirt.

To maximize the synergy between the various cleaning, and dusting tasks,the present methods can be carried out using several varying executionsand instructions for use. In one embodiment, a kit can be provided thathas multiple cleaning pads and solutions for different cleaning tasks.One solution and cleaning pad could be used for surface cleaning andanother solution and pad for dusting. The kit may be sold separatelywith advertising and instructions in each kit being used to explain thebenefits of using the various products together.

It is understood that the component parts of the inventive system 20described above may be manufactured and sold separately or together inthe form of a cleaning system or kit. It should be further understoodthe present invention contemplates a variety of additional alternativeconfigurations and component parts which may be attached within thepivot member receiving cavity 50 of the handle portion 24. A widevariety of alternative interchangeable cleaning implements may besubstituted for the cleaning pad support member 26 described above. Thealternative cleaning implements would preferably include a supportmember with a modular design which includes a universal pivot member orother attachment member similar to that described in the preferredembodiment such that the alternative implements could be usedinterchangeably with the preferred handle portion 24. For example,alternative cleaning implements include but are not limited to asqueegee for cleaning windows, mirrors or other glass structures, a softsurface cleaner such as a lint roller, a glass cleaner including anindexing refill roll, an insect swatter, a dog brush or other groomingimplement, a scrub brush or other cleaning implement etc. Numerous otherpivotally or movably attached cleaning implements are also within thescope of the present invention.

Furthermore, although the preferred embodiment illustrates a handleportion 24 pivotally attached to a cleaning pad support 26, it isrecognized that the present invention is in no way limited to such aconstruction. For example, the inventive cleaning system 20 could beconstructed as a single non-movable piece allowing only surface sprayingof the cleaning fluid. Likewise, the cleaning pad support need not bepivotally attached to the handle portion as described in the preferredembodiment. Numerous alternative embodiments that allow for movement ofthe cleaning pad support 26 in relation to the handle portion are withinthe scope of the invention. The cleaning pad support member 26 andhandle portion 24 may alternatively be slidably connected, bingedlyconnected, bendable or otherwise movable into its various desiredorientations. A spring loaded lock switch could be used to allow 180°rotation of the cleaning pad support member 26. The cleaning pad supportmember 26 could include a centrally located pivot member to allow for360° rotation. Alternatively, the handle portion could be rotatable 360°in relation to the cleaning pad support member 26. Additionally, thehandle portion 24 could include an integral or attachable telescopingextension to allow for dusting or cleaning areas outside of a normaluser's reach.

Additionally, the handle portion as described could be eliminatedcompletely and the fluid reservoir could be arranged to form the handleof the cleaning system. The pivotable attachment member could beattached to the upper end of the fluid reservoir. Further, although thespray bottle described herein is a physically separate module, it willbe manifest that the spray bottle may be directly integrated into, orform the handle portion with which it is associated. The reservoir couldhave a plug that could be removed when filling with fluid.

The cleaning pad support could alternatively be connected to the handleportion via a threaded connection. Such an orientation would allow forthe ease of attachment and removal of the numerous alternative cleaningimplements that are within the scope of the present invention. Thecleaning pad support could also be alternatively arranged to rotate ineither a vertical or horizontal direction to accommodate variouscleaning functions. The cleaning system could further include amotorized spinning head for additional efficacy and less effort onbehalf of the consumer.

Although the cleaning fluid delivery system has been described inreference to the fluid reservoir, it is recognized that alternativeconfigurations for delivering cleaning fluid to a surface to be cleanedor to a cleaning media are also within the scope of the presentinvention. For example, the fluid reservoir could be arranged in amanner such the cleaning fluid is sprayed or applied on the back surfaceof a cleaning pad or cloth and allowed to move through the cloth via awicking action. Alternatively, the attachment members or tines 108 a,108 b of the cleaning system could be in fluid communication with thecleaning fluid reservoir such that cleaning fluid may be discharged on acleaning pad 28 via the attachment members 108 a, 108 b. Such a deliverysystem could deliver cleaning fluid through the tip, bottom, top orlateral sides of the attachment members. Alternatively, the liquiddelivery system could include a flip out nozzle or reservoir configuredfor spraying cleaning fluid onto the cleaning media. Such aconfiguration would eliminate the need for a pivoting support member.

d. Method of Manufacture

A wide variety of molding and manufacturing techniques can be used tomanufacture the cleaning tool 22. In one embodiment, the method ofmanufacture generally includes making a handle 24 with a cradle forreceiving a fluid dispenser 30, connecting a cloth support 26 to thehandle 24, forming a cleaning cloth 28 by tapering fibers and allowingthe cloth 28 to be fixed on the support 26 so that the fibers closestthe handle 24 are shorter than the fibers closest to a free end of thesupport member.

The handle portion 24 is preferably constructed so that a pivot point isdefined by the pivot member receiving cavity 50. The pivot memberreceiving cavity 50 is constructed such that it is located below ahorizontal plane defined by the fluid reservoir 30 and is configuredsuch that the pivot member receiving cavity 50 includes a cantileveredpivot engagement tab 38. The handle is also preferably constructed toprovide for an opening 32 that allows a user single handed access into areservoir receiving cradle 36 contained within the handle 24. Thereservoir receiving cradle 36 is formed to define a plurality of grooves39 configured to engage and lock the spray bottle into the cavity.

Two U-shaped supports or rails 44, 46 are formed within the sidewalls ofthe handle and are molded to receive a spray bottle 30 within. Retentiontabs 42 a, 42 b are also molded into the cradle 36 to frictionallyengage and retain a lower sidewall of the spray bottle 30. Inconstructing the handle the handle 24, a plurality of structural supportribs 39 are formed which extend forwardly toward the pivot memberreceiving cavity 50. A pair of ears 49 a, 49 b are also formed into thehandle 24. The ears are formed to include opposed grooves 52 a, 52 b ,on an inner cavity surface. The grooves 52 a, 52 b , are preferablydimensioned to slidably engage axles 80 a, 80 b of a circular pivotmember 82. The pivot member 82 is formed to include axles 80 a, 80 b.The bottle neck portion of the cradle is formed to define a first bottleneck receiving portion 44.

While a variety of methods may be employed, in one embodiment thecleaning tool 22 is formed using an injection molding process. Themethod includes injecting plastic in a mold to form a handle portion 24of a cleaning tool. The mold is configured to define a handle portion 24having an opening for accessing a fluid reservoir 30. A second mold isused to form a cleaning pad support 26. Plastic is inserted into a moldto form a cleaning pad support member 26. A blow molding process is thenused to form the fluid reservoir 30. In a final step, the parts of thecleaning tool 22 are assembled and packaged for distribution.

Although the best mode contemplated by the inventors of carrying out thepresent invention is disclosed above, practice of the present inventionis not limited thereto. It will be manifest that various additions,modifications and rearrangements of the features of the presentinvention may be made without deviating from the spirit and scope of theunderlying inventive concept.

Moreover, as noted throughout the application the individual componentsneed not be formed in the disclosed shapes, or assembled in thedisclosed configuration, but could be provided in virtually any shape,and assembled in virtually any configuration, so as to provide for acleaning system that includes a cleaning fluid reservoir attached tocleaning implement support. Furthermore, all the disclosed features ofeach disclosed embodiment can be combined with, or substituted for, thedisclosed features of every other disclosed embodiment except where suchfeatures are mutually exclusive.

It is intended that the appended claims cover all such additions,modifications and rearrangements. Expedient embodiments of the presentinvention are differentiated by the appended claims.

1. A cleaning article comprising: a fusible base sheet, the base sheetcomprising an unperforated, uncut outer edge; a fusible holding sheetand a fiber bundle layer including fusible fibers at least in part,wherein the fiber bundle layer is laid on one side of the base sheet andthe holding sheet is laid on the other side of the base sheet; whereinthe base sheet, the fiber bundle layer and the holding sheet arefusion-bonded in a direction to cross fibers in the fiber bundle layer,and wherein the holding sheet is shorter than the base sheet; and aholder and two holding spaces, wherein the holding spaces are providedbetween the base sheet and the holding sheet and wherein the holder isdetachably inserted into the holding spaces.
 2. The cleaning article ofclaim 1, wherein the outer edge is rectangular and is defined by astraight uncut upper edge, a straight uncut lower edge and two straight,uncut side edges.
 3. The cleaning article of claim 1, wherein the outeredge is nonlinear.
 4. The cleaning article of claim 1, wherein theholder comprises: a) a handle portion having an opening configured toallow access to a cradle; and b) a cleaning article support membermoveably attached to the handle portion.
 5. The cleaning article ofclaim 4, wherein the cleaning article support member is moveable betweena first cleaning position and a second cleaning article liquidapplication position.
 6. The cleaning article of claim 5, furthercomprising a cleaning fluid dispenser within the cradle.
 7. The cleaningarticle of claim 6, wherein the cleaning fluid dispenser comprises apump spray bottle.
 8. A cleaning article having a brush portion,comprising; a fusible sheet, the fusible sheet comprising a uniform,unbroken outer edge; and a fiber bundle layer including fusible fibers,the fiber bundle layer being fusion-bonded to the fusible sheet toprovide a brush portion and two holding spaces into which a holder is tobe inserted, the brush portion being composed of the fusible sheet andfibers of the fiber bundle layer.
 9. The cleaning article of claim 8,further comprising: a handle defining an interior recess for receiving afluid reservoir; a cleaning article support pivotably attached to thehandle, the support capable of pivoting rearwardly from a cleaningposition; and a fluid reservoir attached to the handle in the cradle,the reservoir capable of applying fluid to a surface to be cleaned andto the surface of the fiber bundle layer.
 10. The cleaning article ofclaim 9, wherein the cleaning article support comprises a pair ofparallel laterally extending attachment prongs.
 11. The cleaning articleof claim 10, wherein the attachment prongs comprise a plurality ofprojections extending generally vertically from the prongs.
 12. Thecleaning article of claim 11, wherein the projections comprise an angledside sloping away from the handle.
 13. The cleaning article of claim 9,wherein the cleaning article support comprises a pivot member at oneend, the pivot member including a plurality of indentations configuredto receive a semi-flexible engagement tab projecting downward from thehandle.
 14. A cleaning article comprising: a soft and fusible basesheet, the soft and fusible base sheet comprising a solid outer edge;one or more fiber bundle layers, each of which includes fusiblefilaments, wherein the one or more fiber bundle layers are laid on oneside of the base sheet; a first joining portion that joins each of theone or more fiber bundle layers to the base sheet; and at least onesecond joining portion that joins fibers in at least one of the one ormore fiber bundle layers to the base sheet.
 15. The cleaning article ofclaim 14, wherein the cleaning article is attached to a handle portiondefining a cradle for a fluid reservoir and configured to receive thebase sheet; and a cleaning article support member attached to the handleportion.
 16. The cleaning article of claim 15, wherein the cleaningarticle support member is movably attached to the handle portion. 17.The cleaning article of claim 16, wherein the cleaning article supportmember is pivotally attached to the handle portion.
 18. The cleaningarticle of claim 16, wherein the cleaning article support member isslidably attached to the handle portion.
 19. The cleaning article ofclaim 16, wherein the cleaning article support member is moveablebetween a first cleaning position and a second cleaning article liquidapplication position.
 20. The cleaning article of claim 19, furthercomprising a detachable cleaning fluid dispenser within the cradle.